Download Cover Page - NV Series

Installation, Operation
& Maintenance Manual
NV Series
Dehumidifiers
For the latest updated versions of this or other Seresco
Installation, Operation & Maintenance Manuals contact
Seresco Technologies Inc. Tel: (613) 741-3603
Visit: www.serescodehumidifiers.com
Issue Date : 2011-09-30
Issue Date : 2011-09-30
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2
Table of Contents (NV Series).doc
Issue Date : 2011-09-30
Section
Section Title
A
Warnings, Cautions and Notices
Warnings, Cautions and Notices
B
C
D
E
Page(s)
A-1
NE/NP/NV Series General Information
General Information
B-1
Unit Description
B-1
Component Descriptions
B-2
Product Nomenclature
B-3
Unit Label
B-6
Further Information
B-7
Pre-installation Requirements
Pre-installation Requirements
C-1
Receiving Checklist
C-1
Shipping Damage Instructions
C-1
Storage
C-2
Mechanical Installation
Mechanical Installation
D-1
Lifting and Rigging Procedures
D-1
Unit Assembly
D-1
Duct Connections
D-1
Piping and Unit Connections
D-2
Drain Pans – Condensate Drain
D-2
Blower Motor Brace
D-3
Factory Start-up Supervision
D-4
Electrical Installation
Electrical Installation
E-1
Main Panel Power Connection
E-1
Control Wiring
E-2
Websentry Connection
E-3
Remote Operator Panel
E-4
Table of Contents (NV Series).doc
F
G
H
X
Y
Start-up
Start-up
F-1
Pre-Startup Checklist
F-1
Start-up Procedure
F-3
Factory Start-up Supervision
F-6
NE/NP/NV Series Operation
Sequence of Operation
G-1
CommandCenter Operation
G-5
Routine Maintenance
Routine Maintenance
H-1
Routine Maintenance Checklist
H-1
Component Maintenance
H-2
Outdoor Air Balancing
H-5
Troubleshooting
Troubleshooting
X-1
Troubleshooting Steps
X-1
Contacting Service and Technical Support
X-1
Websentry Troubleshooting
X-2
Warranty
Warranty
Z
Issue Date : 2011-09-30
Annex
Y-1
Issue Date : 2011-10-06
Section A - Warnings, Cautions and Notices (NV Series)
Warnings, Cautions and Notices
Throughout this manual, warnings, cautions and notes appear when special care must be taken to avoid potential hazards
that could result in mechanical or electrical damage, personal injury or death.
WARNING Indicates a potentially hazardous situation which could result in serious injury or
death if handled improperly.
CAUTION Indicates a potentially hazardous situation which could result in moderate injury or
equipment damage if handled improperly.
Note : Indicates a situation that could result in equipment damage if handled improperly.
A-1
Section A - Warnings, Cautions and Notices (NV Series)
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A-2
Issue Date : 2011-10-06
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Section B - NV Series General Information
General Information
Use this manual to install, operate and maintain your Seresco Technologies Inc. (Seresco) NV Series dehumidification unit.
Carefully review the procedures and instructions in this manual to minimize installation and operation difficulties. Every
Seresco dehumidification unit is accompanied by a label that identifies the unit serial number, mechanical, refrigeration and
electrical operating information. This information is required when ordering parts or requesting service for a Seresco
dehumidification system. Seresco also publishes a comprehensive natatorium design guide which provides a wealth of
information on how to design a pool. See www.serescodehumidifiers.com for more information.
Unit Description
Seresco's NV Series advanced dehumidifiers are designed for residential or commercial indoor pools and other various
dehumidification requirements.
Figure B-1.
Heat recovery circuit
B-1
Section B - NV Series General Information
Issue Date : 2011-10-06
Component Descriptions
The following components are commonly used on Seresco Technologies Inc.'s NV Series of dehumidifiers. Detailed
technical information can be found in the annex and in the respective manufacturer's IOM manual(s).
Variable Frequency Drives
Used on main fans for air balancing and on exhaust 2 to modulate airflow by changing the frequency of the input power.
Exhaust 2 airflow is modulated according to a 0 – 10V signal from the unit's microprocessor.
Electronically Commutated Motorized Impellers
Used on exhaust 1, the speed of these motors can be modulated by a 0 – 10V signal.
Indirect Gas-Fired Heaters
Used for space heating when the return air temperature is below the set-point. The level of heat is fully adjustable through
the use of a single modulating heater and multiple single-stage heaters (if required).
Actuators
On / Off actuators are used to control dampers on the exhaust outlets, while proportional actuators are used to control
internal dampers that regulate airflow according to a signal from the unit's microprocessor.
B-2
Section B - NV Series General Information
Issue Date : 2011-10-06
Product Nomenclature
The product nomenclature is a 27 character alpha-numeric sequence that completely describes the options present on the
dehumidification unit.
Table B-1. Seresco Technologies Inc. Nomenclature Definition
Natatorium Environmental Control Series
Series
Dash
Tonnage
Dash
Pool Heater
Cabinet
Configurations
Dash
Indoor/Outdoor
Dash
AC Options
Outdoor
Air Options
Version 3.2
NE
Natatorium Protocol Series
NP
Natatorium Ventilation Series
NV
Dash
-
2 ton
002
...16 ton
016
18 ton
018
...80 ton
080
10 ton “double decker”
210
...32 ton “double decker”
232
Dash
-
No Pool Water Heater
N
Pool Water Heater
P
Double walled - Return plenum - Bottom
B
Double walled - Horizontal Return
C
Horizontal -single wall Standard
H
Horizontal - single wall - Mirrored
M
Vertical - single wall Mirrored
N
Double walled - Return plenum - Right Side
R
Double walled - Return plenum - Left Side
S
Double walled - Return plenum - Top
T
Vertical - single wall Standard
V
Special
Z
Dash
-
Indoor Unit
I
Exterior Unit
X
Dash
-
Outdoor Air Cooled Condenser
A
Glycol Cooled By a Fluid Cooler
G
Air Handler (Chilled Water Coil)
H
Water Cooled - Variable Flow (< 65F Water Loop)
M
No Air Conditioning (All AC components removed)
N
Packaged/Integral Air Cooled Condenser
P
Water Cooled - Variable Flow (70-85F Water Loop)
V
None
0
Duct Connection Collar Only
1
B-3
Section B - NV Series General Information
Exhaust Fan
Supply Air
Orientation
External
Static Pressure
Issue Date : 2011-10-06
Duct Collar c/w Manual Damper & Filter
2
OA Inlet Motorized Damper & Filter
3
Purge/Economizer Motorized Damper (In addition to OA Motorized Damper Option)
4
Heat Recovery Package with Motorized Damper and Time Clock
5
Heat Recovery Package Option on OA with Additional Purge/Economizer Option
6
Unit mounted Exhaust fan (Required with HR)
E
Unit mounted Exhaust fan and Purge/Economizer Fan
F
None
N
Unit mounted Purge/Economizer Fan
P
Bottom Supply
B
Top Right Supply
D
Horizontal - Loopback
E
Top Loopback End Supply
F
Top Left Supply
G
Horizontal (Straight Through)
H
Top Horizontal End Supply
J
Left (oriented with airflow air turns left out of unit)
L
Right (oriented with airflow air turns right out of unit)
R
Top Supply
T
0.5"
0
0.75"
4
1.0"
1
1.5"
5
2.0"
2
Other
3
X
Supply Air CFM
XY times 10 to the N
Y
N
Unit mounted electric Heater - Separate power connection
Space Heating
Type
Heating Control
Details
B-4
D
Unit mounted electric heater - Single point power connection
E
Unit mounted gas heating
G
Remote by others
N
Unit mounted steam coil
S
Remote electric heater supplied by Seresco
T
Unit mounted hot water coil
W
Remote electric modulating heater supplied by Seresco
X
Remote hot water coil supplied by Seresco
Y
Remote steam coil supplied by Seresco
Z
Standard control signals: Valve and power supply by others
0
2 stages factory wired electric heating control
1
Modulating - factory supplied and wired valve
2
Section B - NV Series General Information
Issue Date : 2011-10-06
Unit Supply
Voltage
Unit Controls
Refrigerant
Disconnect
Warranties
On/Off - factory supplied and wired Valve
3
Supply isolated 50 VA power for remote valve ( valve by others)
4
Modulating factory wired electric heating control
5
Supply On/Off Valve & 50 VA power for remote valve installation
6
Supply Modulating Valve & 50 VA power for remote valve installation
7
208/1
A
230-240/1
B
208/3
C
230-240/3
D
460-480/3
E
575-600/3
G
Electro-mechanical
0
Command Touch Screen
1
Command Center
2
Command Center c/w Building Communication
3
Command Center c/w Remote Panel
4
Command Center c/w Building Communications & Remote Panel
5
R410A
A
R407C
C
R22
R
Non fused Disconnect
D
Fused Disconnect
F
No Disconnect
N
Standard - 2yrs on driveline, coils, and compressor
0
2 yrs on driveline and compresor, 5 yrs on coils
1
2 yrs on driveline and compressor, 10 yrs on electrofined coils
2
2 yrs on driveline and coils, 5 years on compressor
3
2 yrs on driveline, 5 yrs on compressor and coils
4
2yrs on driveline, 5 yrs on compressor, 10 yrs on electrofined coils
5
2yrs on driveline and coils, 10 yrs on compressor
6
2yrs on driveline, 10 yrs on compressor, 5 years on coils
7
2yrs on driveline 10 yrs on compressor and electrofined coils
8
5yrs on driveline, 2 yrs on compressor and coils
9
5yrs on driveline and coils, 2 yrs on compressor
A
5yrs on driveline, 2 yrs on compressor, 10 years on electrofined coils
B
5yrs on driveline and compressor, 2 yrs on coils
C
5yrs on driveline, compressor and coils
D
5 yrs on driveline and compressor, 10 yrs on electrofined coils
E
5 yrs on driveline, 10 years on compressor, 2 yrs on coils
F
5 yrs on driveline and coils, 10 yrs on compressor
G
5 yrs on driveline, 10 years on compressor and electrofined coils
H
B-5
Section B - NV Series General Information
Unit Label
B-6
Issue Date : 2011-10-06
Issue Date : 2011-10-06
Section B - NV Series General Information
Further Information
For further information, please visit our website at www.serescodehumidifiers.com. Feel free to browse our website and
watch informative videos on every aspect of our products.
B-7
Section B - NV Series General Information
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B-8
Issue Date : 2011-10-06
Section C - Pre-installation Requirements
Issue Date : 2011-09-30
Pre-installation Requirements
Seresco Technologies Inc. inspects and fully tests each dehumidifier in all operating modes before it ships from the factory.
The unit can suffer damage in transit. Check the equipment thoroughly for both visible and concealed damage before you
sign the receiving papers. Document any damage in writing on the carrier’s bill of lading to ensure that damage claims are
handled promptly. If the unit has been damaged, obtain a claim form from the carrier. Promptly fill out and return the form,
and notify Seresco Technologies Inc. of any damage.
Note : Damage claims or missing parts must be filed with the freight carrier.
Receiving Checklist
Note : The shipping protection provided by the factory is for transport purposes only and should not be
relied on to protect the unit in storage or on the job site.
Note : Seresco is not responsible for any shipping damages. Should your unit arrive damaged, please
follow the instructions in Shipping Damage Instructions to resolve the situation. Delivery cannot be refused
on the basis of shipping damages.
Upon receipt, please check the following components for damage:
Verify the proper operation of latches and hinges on all access doors
Inspect all coils for damage to the fin surface coating, headers or coil connections
Manually rotate the fan wheel to ensure free movement of the shaft, bearings and drive
Inspect the fan housings for any foreign objects
Inspect and test all piping for possible shipping damage
Check the tightness of bolts on the fan structure and coils
Inspect fan isolator shipping brackets
Shipping Damage Instructions
Seresco Technologies Inc. ships freight on board (FOB), meaning that the unit belongs to the customer as soon as the
delivery truck leaves the factory. If damage has occurred to the unit during shipment, follow these instructions:
1. Specifically note the extent of the damage in detail on the freight bill. Clear photographs of the damaged
C-1
Section C - Pre-installation Requirements
Issue Date : 2011-09-30
components are required.
2.
Report all claims of shipping damage to the delivering carrier immediately and coordinate a carrier
inspection if necessary.
3. Contact Seresco Technologies Inc. by email at [email protected] or by phone at (613)-7413603 and dial 2 for the soonest available tech support technician. Have the unit serial number (8-digit) and
nomenclature designation (23 digit alpha-numeric sequence starting with the series designation) on hand.
These may be found on the unit label along with other performance and electrical information.
4.
Do not attempt to repair the unit without consulting the Seresco Technologies Inc. Service and Tech
Support Department. It is the receiver's responsibility to provide reasonable evidence that damage was not
incurred after delivery.
Storage
Protection from the elements is required for any unit that will be stored on the job site or a holding area before installation.
For long term storage, a controlled indoor environment is highly recommended. All factory-applied shipping protection
should be removed before the unit is put into storage. Shipping protection material is not suitable protection for short or
long-term storage.
Note :
Standard Seresco warranties expire 24 months from the date of shipment.
See section Y – Warranties for further information.
C-2
Section D - Mechanical Installation (NV Series)
Issue Date : 2011-10-06
Mechanical Installation
WARNING Heavy objects ! Do not use cables (chains or slings) except as shown. Each of the
cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit.
Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for an even unit lift.
Other lifting arrangements may cause damage to equipment, serious injury or death of personnel. Always
place, assemble, and suspend single sections. Do not lift units in windy conditions. Do not raise units
overhead with personnel below unit.
WARNING Improper lifting procedure ! Test lift the unit 24 inches to verify proper operation of
lifting equipment and positioning of lift points such that the unit is level. Failure to properly lift the unit
could result in equipment damage, serious injury or death. Seresco Technologies Inc. is not responsible for
the improper use of lifting equipment.
WARNING When lifting unit, appropriate personal protection equipment (PPE) such as steeltoed boots and hard hats must be worn to avoid potentially serious injury.
Lifting and Rigging Procedures
Determine the approximate centre of gravity before lifting the unit. Consult unit design drawings provided in
the submittal documents to determine total weight and weight distribution.
Never assemble split sections before lifting them to the installation location. Always lift sections as received
from the factory.
Lift sections using the provided lifting lugs
To avoid damage, do not attach intake or exhaust hoods prior to lifting the unit into place.
Unit Assembly (Split Units Only)
Under special conditions, the unit may be split into two or more sections to ease the installation process. Base angles are
attached using 3/8” bolts, and inside angles are bolted using 5/16” bolts. Ensure that all provided holes are used. Caulk
seams on the outside of the unit to make the join air-tight. Install the standing seam roof rib.
D-1
Section D - Mechanical Installation (NV Series)
Issue Date : 2011-10-06
Duct Connections
All duct connections should be installed in accordance with local and national standards. To ensure the highest fan
efficiency, duct turns and transitions should be made to minimize air friction losses and turbulence. See supplied unit
drawing from the submittal for location and size of unit duct connections. Use only flexible duct connectors to connect to
the unit.
Piping and Unit Connections
See the unit label for unit connection line sizes. The installer must endeavour to ensure that all industry standards for
refrigeration component installation are met. This includes but is not limited to; proper line sizing, materials, nitrogen
purging, brazing with Silfos 5 or better (NO SOFT SOLDER), evacuation, cleanliness, traps, long radius elbows and system
charging.
Drain Pans - Condensate Drain
The dehumidifier is a draw through configuration as a result the entire cabinet is under negative pressure. Without a P-trap,
condensate will not drain and the unit will overflow into your mechanical room.
Per Figure 5 pitch the condensate drain line a minimum of 1/8” per linear foot, and support the pipe with codeapproved hangers at least every 5 feet.
If the drain line passes through an unconditioned space, heat tracing is required to prevent the condensate in the
drain from freezing.
When gravity disposal is not possible, a condensate pump can be used. Follow the pump manufacturer’s installation
instructions.
Figure D-1. P Trap
D-2
Section D - Mechanical Installation (NV Series)
Issue Date : 2011-10-06
Blower Motor Brace
Upon installation remove ONLY lower bolt from all four corners shown in Figure D-2 (Detail A). The top of the bolt will
be spray-painted yellow for easy identification. The plug fan sits on spring dampers to minimize vibration translated to the
unit from the fan motor. During shipping, the fan assembly is fixed such that the springs are compressed and cannot
oscillate. Removing these bolts on installation ensures that the the fan vibrations will be dampened correctly.
Figure D-2. Blower Motor Brace
Figure D-3. Double motor assembly – remove horizontal brace on front wall
D-3
Section D - Mechanical Installation (NV Series)
Issue Date : 2011-10-06
Factory Start-up Supervision
Seresco Technologies Inc. factory start-up supervision can be purchased with the equipment. A factory start-up
includes several key services:
The expertise of a factory-trained technician who will supervise the commissioning of the equipment.
This Seresco representative will assist the installing contractor with filling out the Start-Up Report.
They will also inspect the installation to make sure that the dehumidifier has been properly integrated with
the rest of the equipment on the job site.
Finally, they can train the maintenance personnel to operate and service the equipment if necessary.
A factory start-up does not include installation assistance. The installing contractor is responsible for ensuring
that the system is ready for start-up when the Seresco representative arrives. If the system is not ready, Seresco
reserves the right to bill the contractor for a second visit. When the installing contractor is confident the system
will be ready, contact the Seresco Sales representative to schedule the start-up. Please call at least two weeks
before the desired start-up date to prevent scheduling conflicts.
Items required for Start-Up
A service technician and a fully stocked service vehicle.
Air balancing equipment (magnehelic differential pressure gauge).
Volt/Amp/Ohm meters.
A digital thermometer w/clamp on sensors.
Items to be Completed Before Start-up
Leak-check and inspect the unit for internal concealed damage.
Level and support the dehumidifier properly.
Install the outdoor air duct filters and damper (if applicable).
Install the condensate P- trap and drain lines and prime P-trap.
Pipe the remote condenser fan pressure controls to the condenser hot gas lines (if applicable).
Evacuate and leak-check the remote condenser line set (if applicable).
Tighten all electrical connections and verify that the line voltage is correct for the unit.
Install all controls and verify that all field wiring matches the schematic.
Fill and heat the pool and room to design conditions.
Install the pool water piping and a flow meter (if applicable). Purge all air from pool lines.
A complete system air balancing.
D-4
Issue Date : 2011-09-30
Section E - Electrical Installation
Electrical Installation
WARNING Disconnect all electric power, including remote disconnects, before servicing. Follow
proper lockout procedures to ensure that the unit is not accidentally powered. For variable frequency
drives, refer to the appropriate section of the manual. Verify with a voltmeter that all capacitors have
discharged. Failure to disconnect power and discharge capacitors before servicing could result in serious
injury or death.
Note : Use copper conductors only ! Unit terminals are not designed to accept other types of conductors.
Use of aluminium or other wiring may result in galvanic corrosion or overheating.
Note : Properly seal all penetrations made in the outer walls. Failure to due so may result in
unconditioned air entering the unit, water infiltrating the insulation or serious equipment damage. Ensure
that all metal shards and filings are swept to avoid possible corrosion or damage to electrical components.
Main Panel Power Connection
The field-installed power supply wires and over current devices must be sized to handle the minimum ampacity of the
dehumidifier without exceeding the maximum fuse size rating. Both the MCA and MOP are indicated on the unit
nameplate. Figure E-1 shows typical power wiring connections. Single-phase units require 3 wires, 2 power and one ground.
Three-phase units require 3 power wires and one ground wire. Connect the power supply wires to the main power
distribution block located inside the unit main electrical panel. For units with electric heaters and single-point power
connections, the power distribution block is located in the heater. For units with electric heaters and dual-point power
connections, the unit and heater must be powered independently. For units with mounted disconnects, ensure that the power
is brought first to the disconnect and then the power distribution block. Always verify the nameplate voltage before
connecting to the unit.
E-1
Section E - Electrical Installation
Issue Date : 2011-09-30
Figure E-1. Main power distribution block
Control Wiring
Seresco Technologies Inc.'s dehumidifiers have all necessary sensors unit mounted and setpoints pre-programmed at the
factory. Remote duct heaters, outdoor air-cooled condensers, auxiliary pool water heaters and remote exhaust fans all require
interfacing with the dehumidifier. The common connection terminals are identified in Table E-1. For a complete list of
terminal connections and functions, refer to section Z – Annex.
Table E-1. Control Terminals
Pin
I/O's
Description
6
DI14
Freezestat
7
DI15
Firestat
7
AO01
Modulated Heat
Connector J7
Connector J8
Connector J9
1,2
DO24
Space Heater, Stage 2
3,4
DO23
Space Heater, Stage 1
5,6
DO22
Exhaust Fan 2
7,8
DO21
Exhaust Fan 1
9 , 10
DO20
Outdoor Air Damper
1,2
DI19
Outdoor Air Condenser 1
3,4
DI18
Outdoor Air Condenser 2 (Ver. 5.x only)
5,6
DI17
Auxiliary Pool Heater, Pool 2
7,8
DI16
Auxiliary Pool Heater, Pool 1
Connector J10
E-2
Issue Date : 2011-09-30
Section E - Electrical Installation
WebSentry Connection
Requires RJ45 ethernet connection to the unit.
To get access to WebSentry® you need to register a user id with Seresco. Follow these instructions.
1) Go to the Seresco web page at http://www.serescodehumidifiers.com.
2) Select the Login link in the upper right corner.
3) Select the ‘Click here to register’ link in the WebSentry® login box.
4) Fill in the registration form and submit it. The email address will be your user id.
Follow these instructions to login to WebSentry® and view your Seresco unit.
1) Go to the Seresco web page at http://www. serescodehumidifiers.com.
2) Select the Login link in the upper right corner.
3) Enter login credentials in the WebSentry® login box and click Submit button.
4) Once you have logged in you will see a list of all Seresco units you have access to. The very first time you login
the list is empty since you do not yet have permission to see any unit (see Gain Access to Unit).
5) Too see more detailed information for a unit, click the job name link.
6) The main Conditions page shows you the current conditions including a trend graph showing the room
temperature, humidity and optionally the pool water temperature over the past 4 hours.
You can also see current setpoints, logs and some basic unit configuration by selecting the appropriate menu link.
Gain Access to Unit
To gain access to a Seresco unit you need to know the serial number of the unit and the last 6 characters of the MAC
address. The latter is printed on a bar code label on the control board where the network cable is plugged in. You can also
find this information from the System Info page from the key pad (accessible from User Settings). If you are not able to get
to this information you can also contact Seresco and someone will be able to help you get access to the unit.
Controlling Unit
To gain control of unit so that you can change setpoint, restart unit or modify some factory settings, you first have to
Connect to unit and have it maintain a live connection. By default the unit connects once a minute to upload latest sensors
readings and log entries and then disconnects again. Typically this does not take more than one second.
To get a live connection, click the Connect button on any page that has a Connect button. Keep pressing Connect button or
Web browser refresh button until Connect button changes to a Save and Refresh button.
E-3
Section E - Electrical Installation
Issue Date : 2011-09-30
Another indication that unit is live is that the time stamp in the header under the job name changes to Live. Normally the
time stamp tells you the last time the unit connected to the WebSentry® server.
Once a live connection has been established you can change any unit parameter like setpoints and factory settings. From the
conditions page you can also start and stop the main blower and restart the unit. If unit is equipped with a purge feature, you
can also initiate purge from the conditions page.
Remote Operator Panel (ROP)
The Remote Operator Panel (ROP) looks identical to the local keypad but instead of being connected to the main control
board using a data ribbon cable, it uses a RS-485 serial port communication interface. Cat3 or Cat5 twisted pair cables must
be used between the ROP and the main CommandCenter control board.
The other difference between the local keypad and the ROP is that the ROP has its own processor and memory where the
menu system is stored opposed to the local keypad which just a “dumb” terminal displaying the menu system as controlled
by the main control board.
When installing or replacing the ROP you can run into several issues that will prevent the ROP from working properly. This
document covers all steps you need to take to ensure a good communication between ROP and main control board.
Testing Remote Operator Panel at the unit
To rule out any type of problem with the wiring between the unit and the ROP location, use a 3’-5’ wire and connect the
ROP to the main board right at the unit. All troubleshooting guides in this document applies to both testing ROP at the unit
and at its final location.
NOTE! When doing any rewiring like moving wires from J8 to JCOM or moving ROP between final location and testing it
at the unit, make sure the dip switches are in the off position (towards the 1 & 2 label on the dip switch socket). Do not move
to on position until powered up and red LED (L1) is lit up.
Using proper cable
We recommend using a twisted pair Cat3 or Cat5 cable. What is important is that the two signal wires are twisted together.
Twisting the signal wires together acts as a noise filter. If not using this type of cable you can run into communication issues.
E-4
Section E - Electrical Installation
Issue Date : 2011-09-30
Especially if the ROP is far away from the unit. For easier troubleshooting, use the following coloured wires.
Table E-2. ROP Connections
Cat3/Cat5 Wire
Remote Keypad
Orange
J8-1 (+24V)
White/Orange
J8-2 (GND)
Blue
J8-5 (+ 485)
White/Blue
J8-6 (- 485)
J8
Pin 1
Pin 2
Pin 5
Pin 6
JCOM
Pin 5
Pin 4
Pin 6
Pin 7
Connecting wires
Before doing any wiring, ensure there is no power over the wires. Either power unit off or unplug terminal (J8 or JCOM) to
where the ROP is connected. Connect wires to main control board terminal as listed in Table 1. By default you should be
using terminal J8. JCOM is only used as a backup RS-485 port or when more than one RS-485 port is needed. Open up the
back of the ROP and feed wires through the hole of the back plate and connect wires to terminals as listed in Table E-2.
Check communication
Power up unit or plug in terminal block again. If the two power wires are wired correctly you should now see the red L1
LED light lit up in the ROP. If there is power you can now safely activate the signal wires. You do this by moving the two
dip switches (SW1) next to the green terminal block towards the top of the ROP. This is easiest done by using a small flat
head screw driver.
If signal wires are wired up correctly you should see the main sensor screen within a few seconds (possibly the system
startup screen).
If the screen is blank, you see the Welcome screen for more than 10 seconds, or see other messages indicating the ROP is
trying to establish communication, continue reading this document to help you troubleshoot the problem.
No power to ROP (LED L1 not lit up)
First make sure unit is powered up and that the terminal block (J8 or JCOM) is plugged into the main control board.
Make sure wires are wired as listed in Table 1. Make sure that the terminal in the ROP is grabbing onto the copper and not
the insulation. Check this at the main control board as well. There could possible be a kink in the cable causing a broken
wire. Test ROP at unit using a short cable. Try both J8 and JCOM in case there still is no power connecting to J8. If still no
power you most likely have a failed ROP terminal board.
E-5
Section E - Electrical Installation
Issue Date : 2011-09-30
Power to ROP but showing a blank screen
There should never be a blank screen when there is power to the ROP. At the minimum the ROP should show that it is trying
to connect to the main control board. There are only two reasons why there is a blank screen. The ROP has a contrast dial. It
might have been moved so that there is no contrast at all resulting in a blank screen. The contrast dial is a white dial in the
upper left corner next to the terminal board. Use a small screw driver to adjust it. If you see no change at all on the screen
when adjusting the dial, then this is not the problem. The second reason for a blank screen is if the menu program has been
erased from memory. A static chock could possible cause this. All ROP’s are tested at the factory so there should have been a
program installed when the ROP was shipped from factory. Once again, to really rule out a wiring issue, test the ROP using
a short cable right at the unit.
Power to ROP but not establishing a connection
First thing to check is that the two dip switches has been moved up to activate the signal wires. Make sure wires are wired as
listed in Table E-1. Make sure that the terminal in the ROP is grabbing onto the copper and not the insulation. Check this at
the main control board as well. There could possible be a kink in the cable causing a broken wire. Test ROP at unit using a
short cable. Try both J8 and JCOM in case there still is no communication when wired to J8. If still no communication, read
the next section to do one more last test.
Check for communication attempt
From the main control board you are able to look at data streams for anyone of the 3 serial ports. We can use this to
determine if the ROP at least is getting some message through to the main control board. Start up the unit in Service Mode.
Go to the Main Menu (1) and then Service (6) – Network (3) – Console (2). Use arrow keys to select port. Port D is RS-485
on J8 and Port C is RS-485 on JCOM. Select 1 to start serial port monitor console. If there is communication you should see
a bunch of characters within a few seconds. You should also see them changing every few seconds. Stop by pressing 2 or the
Back key. If there is no character stream them most likely the RS-485 communication chip on either the ROP or the main
controller board has failed. There is no way to check which one so if you do not have a second ROP a second board to test
with, there is no way to know. With our newer boards (4.1 and later) we have two RS-485 ports as discussed in this
document so the chances that both communication chips have failed are very small. For these boards we will replace the
ROP with a new one. For older units using a 3.1 board or older, there was only one RS-485 port so for these units we have to
replace both the main controller board and the ROP.
If there is a character stream but still no communication at the ROP, check the serial port communication settings to make
sure they have not been changed. See next section. Check serial port configuration settings. From the Main Menu, go to
E-6
Issue Date : 2011-09-30
Section E - Electrical Installation
Factory Settings (5) – Network (5) – Serial Ports (2). Then select either Port C (JCOM) or Port D (J8) depending on which
terminal you are testing. User should be set to Seresco, Baud Rate to 57600, Databits to 8, Parity to None. The timer Reply
Delay should be at least 500 but new recommendation is 750. The timer Invalid Data should be set to 1000.
Echo Test is by default set to Yes but you can try setting this to No to see if this will establish a connection. By default a RS485 is echoing back every sent message back to the sender. Our controller is using this to test for a robust connection. We
have however seen cases where the RS-485 communication chip partially has failed where it no longer echoes back sent
messages but otherwise functions just fine. By setting the Echo Test to No we can test for this fault.
If you did any configuration change but still no communication you can try doing a System Restart to see if it this will help.
Either power off unit in between or unplug ROP terminal from board to cycle the ROP. If you still are not being able to
establish communication after doing these steps, we have an unknown fault and the ROP needs to be replaced. If this already
is a new ROP, we need to replace the board.
ROP shows Version Mismatch
If the ROP display show Version Mismatch it means you are connecting a ROP to a unit running a software version with
which the ROP is not compatible. Get a new ROP with a version compatible with the software version on the unit.
E-7
Section E - Electrical Installation
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E-8
Issue Date : 2011-09-30
Section F - Startup (NV Series)
Issue Date : 2011-10-06
Start-Up
WARNING Disconnect all electric power, including remote disconnects and discharge all motor
start/run capacitors before servicing. Follow proper lockout procedures to endure the unit cannot
accidentally be powered. For variable frequency drives or other energy storing components, refer to the
appropriate manufacturer's literature for allowable waiting periods for discharge of capacitors. Verify with
a voltmeter that all capacitors have discharged. Failure to disconnect power and discharge capacitors
before servicing could result in serious injury or death.
WARNING Rotating components ! During installation, testing, servicing and troubleshooting of
this product it may be necessary to measure the speed of rotating components. Have a qualified or licensed
service individual who has been properly trained in handling exposed rotating components perform these
tasks. Failure to follow all safety precautions when exposed to rotating components could result in serious
injury or death.
WARNING Live electrical components ! During installation, servicing and troubleshooting of
this product, it may be necessary to work with live electrical components. Have a licensed electrician or
other qualified individual perform these tasks. Failure to follow all electrical safety precautions when
exposed to live electrical components could result in serious injury or death.
Pre-Startup Checklist
A complete start-up is required to ensure that all systems have been configured to ensure optimal and reliable unit operation.
Final adjustments should be made when all space and water temperatures are at design conditions. The use of auxiliary or
portable air heaters may be required to heat the room. Read this section thoroughly before attempting to commission the
Seresco Technologies Inc. dehumidifier. Ensure that the unit installation conforms to all recommendations made by Seresco
Technologies Inc. in this manual. Complete the pre start-up section of the warranty registration / start-up form provided in
section Z – Annex.
Note : Do not use the unit as a construction site heater. Construction material will infiltrate the unit and
can significantly deteriorate unit performance and lifespan.
F-1
Section F - Startup (NV Series)
Issue Date : 2011-10-06
General Checks
Ensure that the unit has been installed on a level location
Check to ensure all packing materials and shipping brackets have been removed from the unit
Verify that any remote space heating coil is installed in the supply air duct (after the unit) and not in the
return air duct (before the unit)
Ensure supply and return air ducts have been connected
Verify damper operation and alignment, as damper blade position may change in shipment
Check that air filters are clean, in place and positioned properly
Remove any debris from the unit interior
Close and secure all unit access door in the airstream
Inspect electrical connections to the unit and unit controllers
Connections should be clean and secure
Compare the actual wiring with provided wiring diagrams
Reference the controls section of this manual for more details on factory mounted controls
Leave this manual with the unit
Fan/Motor-Related Checks
Ensure that fan assembly braces have been removed
Rotate all fan wheels manually to confirm they turn freely in the proper direction
Inspect fan motor and bearings for proper lubrication
Coil-Related Checks
Ensure coil and condensate drain piping connections are complete
Check the piping and valves for leaks. Open and close the valves to check operation
Remove all foreign material from the drain pan
Test the drainage and prime the P-trap by pouring water into the drain pan
Note : For units with water cooled air conditioning. The use of untreated or improperly treated water in
coils may result in scaling, corrosion, erosion, algae or slime. It is recommended that the services of a
qualified water treatment specialist be engaged to determine what water treatment, if any, is required.
F-2
Section F - Startup (NV Series)
Issue Date : 2011-10-06
Electrical Checks
Check nameplate for power requirements and confirm that it matches the available power supply
Voltage must be within ±10% of nameplate voltage. Verify that all field wiring matches provided wiring
schematics. Inspect and tighten all field and factory wiring
Leave power on and allow 24 hours of crankcase heater operation before attempting start-up.
Ensure that the control wiring has been installed to the outdoor condenser / cooler if applicable
Ensure all peripheral controls and sensors are connected and wired correctly
Start-up Procedure
All appropriate fields and sections of the warranty registration / start-up form should be completed. A proper start-up
requires that the unit be run and monitored in all modes of operation at design conditions with the operating data recorded
on the forms provided in section Z – Annex. Seresco's service technicians review every report to ensure all aspects of the
system are functioning within normal operating parameters. Carefully follow the process detailed in the start-up report. If
the space is not at design conditions at the time of start-up, a follow-up visit for final adjustment and balancing is required.
Mail or fax the completed warranty registration / start-up form back to Seresco to validate your unit's warranty See section
Y – Warranty for further information. If you do not have a start-up report, call Seresco for a new copy or download a PDF
version from www.serescodehumidifiers.com.
Note : Warranty is void unless, upon start-up of the unit, the “Warranty Registration and Start-up
Report” is completed and sent to the factory within one week of initial start-up. This report will also
register the compressor warranty with the compressor manufacturer.
Power Turned ON (or after power failure)
When powered, the blower begins to operate immediately and will do so continuously. The microprocessor initiates a selftest and runs systems diagnostics algorithms. If all systems check out, the microprocessor used sensor feedback to resume
normal unit operation. The microprocessor will confirm that the compressor has been off for at least five minutes using its
internal clock.
The CommandCenter keypad display should show current sensor readings and the main menu. For keypad layout and
F-3
Section F - Startup (NV Series)
Issue Date : 2011-10-06
function refer to section G – Nx Series Unit Operation, under CommandCenter operation.
Check time and set-points by doing the following:
Current Time: 1-Main Menu, 4-User Settings, 2-Date&Time
Set-points: 1-Main Menu, 1-Setpoints
Check remote operator panel response, if applicable, and record all data on the start-up forms.
Check Component Operation
To force component operation, do the following:
1-Main Menu, 6-Service, 2-Forced Contacts
To activate, switch component status from OFF/No to ON/Yes, to switch off do the reverse
Ventilation components (under 2-Ventilation) to check include (as applicable) the main blower, condenser fan(s), damper(s),
exhaust fan(s) and purge fan(s) (also known as exhaust 2). Ensure proper, uninhibited rotation of the fans, check and record
amperage readings on the start-up forms.
For heating components (3-Heating), first check whether the space heating option is staged or modulating. To activate
modulated heating, select the modulated option, then use the up and down arrows followed by Enter to select the desired
heating load. To activate Staged heating, enable stage 1 (and stage 2 if applicable).
Note : for units equipped with a gas water boiler and modulated valve, activate stage 1 first to start the
circulating pump(s), then activate modulated heating as described above.
CAUTION Ensure that the main blower is on while testing the heating system or compressor.
Enabling the Compressor(s)
Compressors are disabled after testing at the factory to prevent their accidental non-supervised start-up. To start the
compressor(s):
F-4
Section F - Startup (NV Series)
Issue Date : 2011-10-06
1-Main Menu, 5-Factory Settings, 4-Compressor, 1-Enabled and switch to Yes to enable the compressor
Ensure that design conditions (return air temperature and relative humidity) are established, the main blower is running, and
a gauge set is attached to verify compressor rotation and performance. Make sure that gauge readings correspond to unit
pressure sensor readings shown on the keypad.
Forced Modes
Check unit condition under different modes of operation by doing the following:
Set forced demands: 1-Main Menu, 6-Service, 1-Forced Demands, 1-Compressor 1
To run the unit in dehumidification mode, choose Dehumidify and check pressure, temperature readings. Allow the
compressor to run for 20-30 minutes and ensure that the superheat is within 19-22°F, making adjustments if required. Record
all data.
To run the unit in dehumidification and pool heat modes, select Pool Heat while the compressor is still running. Make sure
that design water flow is provided to the unit. Record actual water flow GPM and pressure.
Confirm and record superheat data. Deselect dehumidification and pool heat modes by selecting OFF/No and allow the
compressor to pump down.
To run the unit in air conditioning mode, select 2-A/C, then air conditioning and pool heat modes. Follow procedure
outline above, recording all data on the start-up forms.
For units with two or more compressors, complete the process for each compressor individually, and finally both together.
To restart the unit in normal mode, do the following:
1-Main Menu, 6-Service, 6-Commission, 2-Commissioned and switch to ON/Yes
1-Main Menu, 3-System, 3-System Restart, 1-Yes
After the system shuts down and restarts, select Normal Mode
Submit the completed start-up report by Fax: 1-613-741-3375 or e-mail: [email protected].
F-5
Section F - Startup (NV Series)
Issue Date : 2011-10-06
Factory Start-up Supervision
Seresco Technologies Inc. factory start-up supervision can be purchased with the equipment. A factory start-up includes
several key services:
The expertise of a factory-trained technician who will supervise the commissioning of the equipment.
This Seresco representative will assist the installing contractor with filling out the Start-Up Report.
They will also inspect the installation to make sure that the dehumidifier has been properly integrated with
the rest of the equipment on the job site.
Finally, they can train the maintenance personnel to operate and service the equipment if necessary.
A factory start-up does not include installation assistance. The installing contractor is responsible for ensuring that the
system is ready for start-up when the Seresco representative arrives. If the system is not ready, Seresco reserves the right to
bill the contractor for a second visit. When the installing contractor is confident the system will be ready, contact the Seresco
Sales representative to schedule the start-up. Please call at least two weeks before the desired start-up date to prevent
scheduling conflicts.
Items required for Start-Up
A service technician and a fully stocked service vehicle.
Air balancing equipment (magnehelic differential pressure gauge).
Volt/Amp/Ohm meters.
A digital thermometer w/clamp on sensors.
Items to be Completed Before Start-up
Leak-check and inspect the unit for internal concealed damage.
Level and support the dehumidifier properly.
Install the outdoor air duct filters and damper (if applicable).
Install the condensate P- trap and drain lines and prime P-trap.
Tighten all electrical connections and verify that the line voltage is correct for the unit.
Install all controls and verify that all field wiring matches the schematic.
Fill and heat the space to design conditions.
A complete system air balancing.
F-6
Issue Date : 2011-10-06
Section G - NV Series Unit Operation
NP Series Unit Operation
Sequence of Operation
Power-ON
After an initial short delay for microprocessor elf-test and diagnostic routines, the blower starts and operates continuously.
After 60 seconds of blower operation, sensor readings have stabilized and the unit modulates outdoor air intake and exhaust
air to heat, cool or dehumidify based on sensor feedback. The unit delivers a constant level of air continuously to the
Natatorium (see unit label for design airflow).
Continuous Blower Operation
Units have been factory wired for continuous blower operation. This helps prevent air stratification and stagnation. This is
also required to ensure that the sensors produce accurate data.
Space Heating Option
When the return (or optionally the space temperature) air temperature is below the set-point, the microprocessor sends a
signal to the gas furnace to ignite. The gas control valves will modulate flow based on return air temperature, or optionally
the space temperature.
Outdoor Air / Exhaust Air Control
On temperature or RH increase above set-point, the outdoor air and the exhaust air airflow increases from minimum levels
incrementally to control the indoor conditions. During warm summer months, the system will be in 100% outdoor air mode.
Optionally, on RH drop below set-point the outdoor and exhaust air will reduce below minimum values to reduce cold
winter operating costs.
Purge-Ventilation Mode
This mode has a timed duration (8-15 minutes adjustable) after which the system automatically resumes normal operation.
When triggered by the operator, the system goes to 100% outdoor air ventilation mode.
G-1
Section G - NV Series Unit Operation
Issue Date : 2011-10-06
Heat Recovery
Once the outdoor air temperature falls below the heat recovery set-point (65 °F, adjustable) the glycol pump shall operate and
circulate glycol between exhaust air and outdoor air heat recovery coils.
The energy a room loses from the exhaust air, as a result of the fresh air requirements, can represent up to 50 % of the
room's heating requirements. Approximately 50-60 % of this exhaust heat can be recaptured with a heat recovery loop. By
doing so it supplies heat to warm the cold outside air and can provide generous energy savings to the room to reduce heating
costs. During freezing weather conditions the outdoor air can provide much of the dehumidification required, and
minimizing the time the compressors run offsetting some of the running electrical costs.
Our typical energy recovery loop consists of two glycol coils: one in the outside air intake and the other in the exhaust airstream. The coils are connected in counter-flow closed loop piping system. The system comprises an inline fluid cooled
pump, an air separator, and in some larger systems a pressure tank and pressure gauge. By circulating a glycol mixture,
typically 30%, we can extract enough heat from exhaust air stream to preheat the outside air intake to about 50-60% of the
room temperature. Extracting more heat from the exhaust air stream is possible but would also lead to possibly freezing of
the exhaust air and would require a more complex and costly system of frost prevention. Keeping our effectiveness down to
50-60% reduces initial cost and keeps things simple.
Figure G-1. Heat recovery loop
G-2
Issue Date : 2011-10-06
Section G - NV Series Unit Operation
Types of Solutions
We recommend and typically use ethylene glycol in our systems but local codes or building requirements may specify
propylene glycol mixtures. The higher viscosity of propylene means a stronger pump is required or a lower circulating water
flow will occur. So it is best to contact the factory if a switch from one glycol to another is preferred. It is important to use
corrosion inhibitors and in the correct amount. When adding the corrosion inhibitor solution please followed the suggested
instructions for the required quantity of fluid. Seresco strongly recommends that the glycol, if not already mixed, be mixed
with distilled water. Topping up and pressurizing the system can be done with clean tap water. In municipalities where local
tap water has a high mineral content, Seresco strongly advises the use of distilled water to prevent “sludging” and premature
failure.
Annual testing should be made of the fluid solution to ensure the adequate glycol concentrations and corrosion inhibitor
protection. Freeze point and PH test strips are available from your local plumbing supply house. It is important to ensure the
solution will not freeze in the case of a power failure or that it is not acidic and will corrode the system. The glycol mix
should be replaced after 5 years or when quality is deem unsatisfactory and cannot be restored.
Filling or Refilling the Glycol Loop
When filling the system please insure all air has been removed. Air in the system will cause corrosion and improper
functioning of the pump. Do not run the pump for any extent time with air in the system it will foam up the glycol and this
will make it difficult to remove the air. If this happens pressurize the system with some water to about 15 PSI and let stand
overnight. Before restarting vent as much air as possible running the pump for very short burst to move the water and any
possible air bubbles around slowly to the vents. For systems with a pressure tank keep the system under a 10-15 PSI positive
pressure to ensure no air get into the system. If the system is left dry for any period of time electrically disable the pump to
avoid it possible coming on without fluid in the system. Please keep record, near the unit, the type of glycol used; ethylene or
propylene, the two types should not be mixed. Keep careful track of what percentage by volume was used and when it was
changed. And the last time it was checked.
G-3
Section G - NV Series Unit Operation
THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK
G-4
Issue Date : 2011-10-06
CommandCenter Operator Panel
Introduction
This document describes the different features of the Operator Panel (local or remote) that is used with the
Seresco units.
Startup Screens
When the unit start up you will see the following menu screen. A 60 second timer is started and if no selection is
made before timer expires, Normal Mode will automatically be selected.
1.
2.
Normal Mode
Service Mode
Selecting Normal Mode will take you to the main sensor screen. If the voltage monitor fault signal is not active,
blower will start right away. If voltage monitor fault signal is active, 60 second timer will continue running.
When timer expires, the voltage monitor fault signal will be checked again. If signal now is cleared, the blower
will start, otherwise blower will remain off and there will be a voltage monitor fault alarm.
Navigation Mode and Edit Mode
The menu system implements two different modes where the keys have different meanings. Navigation mode is
used to navigate the menu system and Edit mode is used when changing data.
The following keys are used in Navigation mode:
•
•
•
•
•
Keys 1-3 (and 4-6) are used to select a menu item. If there are more than 6 menu items, menu items will be
listed 1-3 on every screen.
Up and Down arrows are used to scroll up or down a page. Arrows at the top right corner indicates which
direction you can scroll. If no more than 6 items either down or up arrow will be displayed (no scrolling
“around corner”). If more than 6 menu items, both arrows will be displayed and you can scroll “around the
corner”. Obviously no arrows when 3 or less menu items.
Back key takes you back to previous menu level.
Enter key has a special meaning. From any menu screen it will take you directly back to the main screen (the
sensor screen). If you now press the Back key it will take you back to the screen where you were before
pressing Enter. On the sensor screen you can still use the Up and Down arrows to scroll up and down a page
and the Back key will still take you back to where you were before pressing Enter. If you press 1 however
(Main Menu) the back shortcut is lost (it’s not a true history list yet).
Key 3 on the sensor screen is another hidden feature. It will toggle sensor readings between displaying
values with a one decimal prevision and no precision. Default is no precision. This applies to all
temperatures and the humidity level.
G - NV Series CommandCenter Operation
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10/6/2011
To enter Edit mode you select the number key corresponding to the data item you want to edit on a navigation
screen with data items. To indicate that you are in edit mode, the data value is highlighted.
The following keys are used in Edit mode:
• Keys 1-3 are not used.
• Up and Down arrows are used to scroll up and down in the value list. More info about different types of
data items later in this document.
• Back key takes you back to navigation mode and cancel any changed data. Data is with other words not
saved when you press the Back key.
• Enter key will save the data and most of the time take you directly back to navigation mode (covered
under data types).
Data Types
Most of the data (properties) you can change are changed using values in a selection list. You use the Up and
Down arrows to scroll up and down in the selection list. You can scroll “around the corner”. For data items with
only two selection items (e.g. Yes/No), you can use either the up or down key to toggle between the two values.
Most Integer values are edited as lists with a min and max range. The value might also be restricted to be
changed in specific increments (e.g. 5, 10, 15, 20, …). In a few rare cases integer values are entered one digit a
time. When entering edit mode, the integer value will be displayed as a five digit zero padded number. To enter
a number less than 5 digits, leave the first digits at 0. Press Enter until all digits are set.
Date and Time values are edited in a special way. Using date as an example, when entering edit mode, the year
(or last two digits of the year) will be highlighted. Use Up and Down arrows to change year. When done, press
Enter. Now the month will be highlighted and you change it in the same way. Press Enter again and the day is
highlighted. Pressing Enter a final time will save the new date. Pressing Back at any time when editing the date
will cancel the change operation and take you back to navigation mode.
A time value is entered in the same way as a date.
An IP address is entered the same way as date and time except that you edit one digit at a time.
Passwords are entered one digit at a time pressing Enter after each digit.
Information Messages
Certain actions and certain conditions will generate information messages. Information messages will popup
over current menu screen. The message can be cleared by pressing either key 1 or 2. Key 1 will clear current
message and key 2 will clear all queued messages. Messages can be of three different types. Short, Long or
Confirmed. A short message will be cleared automatically after 3 seconds (default). A long message will be
cleared after 5 minutes (default). A confirmed message will never be cleared (unless there is a system restart)
and have to be cleared by pressing key 1 or 2.
G - NV Series CommandCenter Operation
Page 2
10/6/2011
Menu Structure Quick Reference
The root menu screen is where you see all the sensors and one menu option that takes you to the Main Menu.
Some menu selections are dependent on current unit configuration and will not always be displayed. These
menu selections are marked as Optional.
For data menu items, the default value is displayed in the summary.
1.
User Settings
1.1.
Setpoints
1.1.1.
Temperature
1.1.2.
Humidity
1.1.3.
Freezestat
1.1.4.
Purge Temp
1.1.5.
Economizer
1.1.6.
Heat Recovery
1.2.
Date & Time
1.2.1.
Date
1.2.2.
Time
1.2.3.
Zone
1.2.4.
Date Format
1.2.5.
Time Format
1.3.
System Info
1.4.
Occupied Schedule
1.4.1.
Empty
1.4.1.1.
Day(s)
1.4.1.2.
On
1.4.1.3.
Off
* 1.3.2 – 1.3.3 same as 1.3.1
1.5.
Filter Schedule
1.5.1.
Date
1.5.2.
Interval
1.6.
Display
1.6.1.
Backlight
1.6.2.
Temp Unit
1.6.3.
Reset Display
1.7.
User Password
1.7.1.
Enabled
1.7.2.
Password
1.7.3.
Retention
1.8.
Remote OP
1.8.1.
Version Info
1.8.2.
Port Configuration
G - NV Series CommandCenter Operation
* Only visible on Remote OP
Page 3
10/6/2011
2.
Alarms
2.1.
2.2.
3.
Current Alarms
Alarm Log
System Control
Start/Stop Blower
System Restart
System Status
3.3.1.
Environment
3.3.2.
Ventilation
3.3.3.
Network
3.3.4.
Serial Ports
3.3.5.
Control Status
3.4.
Purge
3.1.
3.2.
3.3.
4.
Factory Settings
Ventilation
4.1.1.
Options
4.1.1.1.
Purging
4.1.1.2.
Economizer
4.1.1.3.
Eco Offset OA
4.1.1.4.
Eco Offset DP
4.1.1.5.
Mod Steps
4.1.1.6.
Fire Reset
4.1.2.
Exhaust Fans
4.1.2.1.
Fan 1 Capacity
4.1.2.2.
Unoccupied
4.1.2.3.
Occupied
4.1.3.
Dampers
4.1.3.1.
Unoccupied
4.1.3.2.
Occupied
4.1.3.3.
OAD 1 Max
4.1.3.4.
OAD 2 Min
4.1.3.5.
OAD 2 Max
4.1.4.
Timers
4.1.4.1.
Stabilize
4.1.4.2.
Freezestat 1
4.1.4.3.
Freezestat 2
4.1.4.4.
No Airflow
4.1.4.5.
VFD Delay
4.1.4.6.
Econo Stable
4.2.
Space Control
4.2.1.
Room Temperature
4.2.1.1.
Deg*Min On
4.2.1.2.
Deg*Min Off
4.1.
G - NV Series CommandCenter Operation
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10/6/2011
4.2.1.3.
Setpoint Adj
4.2.2.
A/C
4.2.2.1.
Sensor
4.2.2.2.
Deg*Min On
4.2.2.3.
Deg*Min Off
4.2.3.
Heating
4.2.3.1.
Type
4.2.3.2.
Deg*Min On
4.2.3.3.
Deg*Min Off
4.2.3.4.
Sensor
4.2.3.5.
Mod Step Size
4.2.3.6.
Stage 2 On
4.2.4.
Humidity
4.2.4.1.
Deg*Min On
4.2.4.2.
Deg*Min Off
4.2.5.
Deadbands
4.2.5.1.
Air Temp Low
4.2.5.2.
Air Temp High
4.2.5.3.
Humidity Low
4.2.5.4.
Humidity High
4.2.5.5.
Heat Rec High
4.2.5.6.
SA Temp Low
4.2.5.7.
SA Temp High
4.3.
Network
4.3.1.
TCP/IP
4.3.1.1.
DHCP
4.3.1.2.
IP
4.3.1.3.
Mask
4.3.1.4.
GW
4.3.1.5.
DNS
4.3.1.6.
Link Monitor
4.3.2.
Serial Ports
4.3.2.1.
Port B (RS-232)
4.3.2.1.1.
User
4.3.2.1.2.
Baud Rate
4.3.2.1.3.
Databits
4.3.2.1.4.
Parity
4.3.2.1.5.
Flow Control
4.3.2.1.6.
Reply Delay
4.3.2.2.
Port C (RS-485)
4.3.2.2.1.
User
4.3.2.2.2.
Baud Rate
4.3.2.2.3.
Databits
4.3.2.2.4.
Parity
4.3.2.2.5.
Echo Test
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4.3.2.3.
Port D (RS-485)
4.3.2.3.1.
User
4.3.2.3.2.
Baud Rate
4.3.2.3.3.
Databits
4.3.2.3.4.
Parity
4.3.2.3.5.
Echo Test
4.3.3.
WebSentry
4.3.3.1.
Enabled
4.3.3.2.
IP
4.3.3.3.
Port
4.3.3.4.
Comm Interval
4.3.3.5.
Comm Segment
4.3.3.6.
Stay Alive
4.3.4.
BACnet
4.3.4.1.
Enabled
4.3.4.2.
Interface
4.3.4.3.
Device ID
4.3.4.4.
Port
4.3.4.5.
Heartbeat
4.3.5.
Modbus
4.3.5.1.
Device ID
4.3.6.
LON
4.3.6.1.
Enabled
4.3.6.2.
Interface
4.3.6.3.
Refresh Rate
4.4.
Inputs/Outputs
4.4.1.
Sensor Type
4.4.1.1.
Return Air
4.4.1.2.
RA Humidity
4.4.1.3.
Outdoor Air
4.4.1.4.
OA Humidity
4.4.2.
Sensor Usage
4.4.2.1.
Return Air
4.4.2.2.
RA Humidity
4.4.2.3.
RA Dew Point
4.4.2.4.
Outdoor Air
4.4.2.5.
OA Humidity
4.4.2.6.
OA Dew Point
4.4.2.7.
Supply Air
4.4.2.8.
Exhaust Air
4.4.2.9.
Blower VFD
4.4.2.10.
Exhaust VFD
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[Optional]
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4.4.3.
Sensor Calibration
4.4.3.1.
Return Air
4.4.3.2.
RA Humidity
4.4.3.3.
RA Dew Point
4.4.3.4.
Outdoor Air
4.4.3.5.
OA Humidity
4.4.3.6.
OA Dew Point
4.4.3.7.
Supply Air
4.4.3.8.
Exhaust Air
4.4.3.9.
Blower VFD
4.4.3.10.
Exhaust VFD
4.4.4.
AO Polarity
4.4.4.1.
Modulated Heat
4.4.4.2.
Exhaust Fans
4.4.4.3.
OA Damper 1
4.4.4.4.
OA Damper 2
4.4.5.
Digital Inputs
4.4.5.1.
Blower On/Off
4.4.5.2.
Space Heater
4.4.5.3.
Occupied
4.4.5.4.
A/C Override
4.4.5.5.
Heat Override
4.4.5.6.
Freezestat
4.4.5.7.
Exhaust 1 OL
4.4.5.8.
Exhaust 2 OL
4.4.5.9.
Heat Rec OL
4.4.6.
Sample Rates
4.4.6.1.
AI Samples
4.4.6.2.
AI Sample Rate
4.4.6.3.
Refresh Sens
4.4.6.4.
DI Samples
4.4.6.5.
DI Sample Rate
4.4.7.
Assignments
4.4.7.1.
Analog Inputs
4.4.7.1.1.
Return Air
4.4.7.1.2.
RA Humidity
4.4.7.1.3.
Supply Air
4.4.7.1.4.
Outdoor Air
4.4.7.1.5.
OA Humidity
4.4.7.1.6.
Exhaust Air
4.4.7.2.
Analog Outputs
4.4.7.2.1.
Modulated Heat
4.4.7.2.2.
Exhaust Fans
4.4.7.2.3.
OA Damper 1
4.4.7.2.4.
OA Damper 2
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4.4.7.3.
4.4.7.3.1.
4.4.7.3.2.
4.4.7.3.3.
4.4.7.3.4.
4.4.7.3.5.
4.4.7.3.6.
4.4.7.3.7.
4.4.7.3.8.
4.4.7.3.9.
4.4.7.3.10.
4.4.7.4.
4.4.7.4.1.
4.4.7.4.2.
4.4.7.4.3.
4.4.7.4.4.
4.4.7.4.5.
4.4.7.4.6.
5.
Digital Inputs
Blower On/Off
Space Heater
Occupied
A/C Override
Heat Override
Freezestat
No Airflow
Dirty Filter
Exhaust 2 OL
Heat Rec OL
Digital Outputs
Exhaust Damp 1
Exhaust Damp 2
RA Damper
Heat Recovery
System Status
Network Dev
Service
[Optional]
5.1.
Force Demands
Enabled
Ventilation
Occupied
5.2.
Force Contacts
5.2.1.
Reset All
5.2.2.
Ventilation
5.2.2.1.
Blower
5.2.2.2.
OA Damper 1
5.2.2.3.
Exhaust Damp 1
5.2.2.4.
OA Damper 2
5.2.2.5.
Exhaust Damp 2
5.2.2.6.
Exhaust Fans
5.2.2.7.
RA Damper
5.2.2.8.
Heat Recovery
5.2.3.
Heating
5.2.3.1.
Heat Stage 1
5.2.3.2.
Heat Stage 2
5.2.3.3.
Modulated Heat
5.3.
Network
5.3.1.
Ping
5.3.2.
Console
5.4.
Clear Alarm Log
5.5.
Clear All Logs
5.6.
Commission
5.1.1.
5.1.2.
5.1.3.
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5.6.1.
5.6.2.
Tested
Commissioned
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Menu Structure Description
This is a more detailed description of each menu item.
1.
1.1.
1.2.
User Settings
Setpoints
If user password has been enabled, you will need to enter the password before you can change
any setpoint.
Date & Time
In this section you set system time properties. You can set the date, time and time zone. You can
also set what date time format that should be used.
Date is always edited in Year-Month-Day syntax and the time is always edited in 24-hour clock
format not matter what the format settings are.
Time zone can be set to -3:30, -4:00 to -10:00 and GMT time.
The following date formats are supported:
Y-M-D, D/M/Y, M/D/Y and Full.
The last format will be spelled out as Jan 1, 2006.
Clock is either a 12 or 24-hour clock.
Note that if the unit is connected to the Internet, you do not need to set the clock. The clock will
automatically be synchronized with a time server. Time zone and date/time formats still needs to
be set.
1.3.
System Info
The System Info screen lists some useful information when troubleshooting the system like
Software and Board version, current IP and MAC address.
1.4.
Occupied Schedule
If user password has been enabled, you will need to enter the password before you can change
the schedule.
You can enter up to 3 scheduled items. Each item determines when the room is Occupied by
specifying a start time and a stop time. You also specify which day of the week the scheduled
item applies (Monday-Sunday, Workdays, Weekends or All).
If there are conflicting items then the priority goes to day items (Monday-Sunday) followed by
Workday and Weekends and last All. Use this to your advantage by specifying a default schedule
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using All and then add a schedule item for days where the default does not apply (e.g. Weekends,
Sunday).
1.5.
Filter Schedule
Use the filter schedule to determine how often there will be a Dirty Filter alarm reminding you
that all filters should be replaced.
Date shows the next date a Dirty Filter alarm will be tripped. You can manually change this date
to any date you like.
Interval specifies number of months until next Dirty Filter alarm after the alarm has been
cleared. Note that the alarm will not be cleared on a system restart. You have to clear the alarm
from the active alarms list. When cleared, the date for next alarm will automatically be changed
to a date using this interval and the current date.
1.6.
Display
Use Backlight to enable/disable the keypad backlight.
Use Temp Unit property to set temperature unit to be used in the system (Celsius or Fahrenheit).
Reset Display controls how long the operator panel will stay idle at a menu screen before being
returned to the main sensor screen.
1.7.
User Password
Here you can enable user passwords (disabled by default). You can also change the user
password and set for how long the user password protected menu items should stay open after
they have been unlocked (retention time).
1.8.
Remote OP
This menu selection is only visible on a remote OP (operator panel connected to the board using
a serial port).
Under version info you can see the software version of the remote OP as well as the minimum
main board software version required to be able to communicate with a main board.
Port Configuration is used to configure the remote OP end of the serial port interface.
Baud Rate sets the speed of the connection.
Echo Test defines if we will do an echo test every time we transmit data over the port. Normally
all data should be echoed back and therefore adding the echo test enable us to have one more test
to ensure data was transmitted with no errors. However, if there is a minor hardware problem
with the port chip, this will cause the port not to work at all. Disabling the echo test might enable
us to still use the port even with the hardware error.
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Reply Delay defines for how long we will wait for a reply message before considering it a
communication fault.
2.
Alarms
2.1.
Current Alarms
The current alarm lists shows all alarms that have not been cleared. You can clear an alarm by
selecting the alarm using number key and then pressing the Enter key to clear the alarm,
Note that some alarms are tied to a physical device that automatically will clear the alarm when
device clear the fault condition. You can still clear this alarm from the alarm list but the alarm
will trip right away if the device has not cleared the fault.
2.2.
Alarm Log
The alarm log lists all alarms since the alarm log last was cleared (from the Service menu). Most
recent alarm at the top. The top line shows the date for selected alarm.
Use arrow keys to select an alarm. Selected alarm is indicated by an arrow in the left margin. The
alarm log will scroll one alarm at a time rather than a page at a time. If pressing the up key when
the first alarm is selected, alarm log will be refreshed.
3.
3.1.
System Control
Start/Stop Blower
Start and stop main blower.
Note that the blower might not come when turning it on. There can be an alarm condition
preventing it from starting (e.g. blower overload, voltage monitor fault or firestat).
When selecting Normal Mode at startup, the blower will automatically be started. To not run the
blower you will have to go to this menu and turn blower off. There might be up to a minute delay
before blower starts due to the voltage monitor fault signal not being cleared.
When selecting Service Mode at startup, the blower will not be started.
3.2.
System Restart
When selecting System Restart you will see a confirmation screen where you have to confirm
that you want to restart the system. Pressing 2 or the Back button will cancel this request.
3.3.
System Status
The status screen shows the status for different internal system components. Its main purpose is
for troubleshooting a running system where the information here can be passed back to tech
support.
The status feature has been grouped into 6 areas.
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Environment shows status for the environment control (Air Temp and Humidity) including air
heater.
The ventilation area shows the status of the different ventilation related components (including
heat recovery).
The network area shows the status for network related components.
The serial ports area show serial port status.
The control status area shows internal control parameters.
3.4.
Purge
By selecting the Purge menu item you will get to the Purge activation screen. At this screen you
can set the length of time the system will purge and start/stop purging.
At the bottom of the screen you can see the current status. It can show Off, PendingPurge or
number of minutes remaining of ongoing purge.
PendingPurge means that we are waiting for the compressor(s) to stop before we can start
purging. The compressors have been notified that they need to stop
Note that you only can start purge if Purge has been enabled under Factory Settings.
4.
Factory Settings
To access these settings you need to enter a service password.
4.1.
4.1.1.
Ventilation
Options
Purging enables and disables the purging feature.
The Economizer property determines how the economizer feature will be used. Setting it to
None disables the feature, setting it to A/C enables it for cooling only, setting it to Dehum
enables it for dehumidification only and sertting it to Full enables it for bot cooling and
dehumidification.
Eco Offset OA is an offset below return air setpoint. The return air setpoint minus this offset is
the highest outdoor air temperature at which the economizer will start. The minimum outdoor air
temperature is controlled by the economizer setpoint.
Eco Offset DP is an offset below return air dew point. The return air dew point minus this offset
is the highest outdoor air dew point at which the economizer will start.
Mod Steps defines in how many steps the exhaust fans will ramp out from occupied mode fan
speed to full speed.
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Fire Reset property controls how the system will recover after a Fire Alarm. When set to auto,
system will automatically go back to normal once the alarm is cleared. When set to Manual, a
System Restart is required to make the system operational again.
4.1.2.
Exhaust Fans
Fan 1 Capacity defines the fan 1 to fan 2 ratio. If both fans are the same size, leave at 50%.
Otherwise determine in percentage the size of fan 1 compared to the size of both fans combined.
Unoccupied defines fan usage in unoccupied mode. Value based on total fan capacity.
Occupied defines fan usage in occupied mode. Value based on total fan capacity.
4.1.3.
Dampers
Unoccupied defines OAD 1 position in unoccupied mode.
Occupied defines OAD 1 position in occupied mode.
OAD 1 Max defines OAD 1 position when exhaust fan runs at full speed. OAD 1 will modulate
between occupied and max position as exhaust fan 1 changes speed.
OAD 2 Min defines the OAD 2 position when exhaust fan 2 runs at minimum speed. OAD 2 will
modulate between min and max position as exhaust fan 2 changes speed.
OAD 2 Max defines the OAD 2 position when exhaust fan 2 runs at maximum speed.
4.1.4.
Timers
Stabilize is how long time system will wait for sensors to stabilize after blower has started. No
other components will start until sensors are stable.
Freezestat 1 is the Freezestat 1 alarm debounce timer. Freezestat 1 is tripped when supply air
drops below the freezestat setpoint.
Freezestat 2 is the Freezestat 2 alarm debounce timer. Freezestat 2 is tripped if supply air drops
stays below the freezestat setpoint after Freezestat 1 has been tripped.
No Airflow property is the No Airflow debounce timer.
VFD Delay property is used to control for how long unit will wait to start exhaust fan 1 after
exhaust damper has started to open. This timer is also used for delaying purge fan 1 after purge
damper has started to open.
Econo Stable property is a stabilizing timer used every time unit is increasing or reducing the
number of purge fan stages.
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Purge Time is for how long time purge will run when started. Setting it to 0 means purge will
run until manually stopped.
Dirt Filt Dly property is the Dirty Filter debounce timer if the dirty filter switch has been
enabled.
4.2.
4.2.1.
Space Control
Room Temperature
The Deg*Min On/Deg*Min Off properties controls for how long the control logic will
wait until increasing or decreasing the supply air setpoint.
Setpoint Adj determines number of degrees to increase or decrease the supply air
setpoint every time setpoint is changed.
4.2.2.
A/C
The Sensor property determines how cooling will be controlled. Supply means that space
temperature will be controlled by using supply air sensor only. Return means that the
space temperature will be controlled by the Room Temperature controller using the return
air sensor.
The Deg*Min On/Deg*Min Off properties controls for how long the control logic will
wait until adding or removing a Cooling stage after a stage has been added/removed.
4.2.3.
Heating
Type sets heating type.
The Deg*Min On/Deg*Min Off properties controls for how long the control logic will
wait until adding or removing a Heating stage after a stage has been added/removed.
The Sensor property determines how heating will be controlled. Supply means that space
temperature will be controlled by using supply air sensor only. Return means that the
space temperature will be controlled by the Room Temperature controller using the return
air sensor.
Mod Step Size defines the increments for the modulated signal when heater is configured
as a modulated heater.
Stage 2 On controls when the second stage digital output will be turned on for a
modulated heater. First stage is turned on when heating is started.
4.2.4.
Humidity
The Deg*Min On/Deg*Min Off properties controls for how long the control logic will
wait until adding or removing a Dehumidification stage after a stage has been
added/removed.
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4.2.5.
4.3.
4.3.1.
Deadbands
This section is used to configure setpoint deadbands. Air temperature deadbands can be
set in 1/10th of a degree.
Network
TCP/IP
Set DHCP to use Dynamic IP and set it to No to use Static IP. In the first case, the IP,
Mask, GW and DNS property will be set automatically and you will be able to see what
they are set to (as soon as a network connection has been detected and a DHCP server has
been found).
IP is the systems IP address.
Mask is the network mask.
GW is the IP address for the gateway.
DNS is the IP address for the Domain Name Server.
Link Monitor is how often the system will check that there still is a physical network
link. If you unplug the Ethernet cable, it can take up to this time before it is detected.
Start Device is a timer that is used at startup of a network device. The Network Device
digital output has to be assigned to a terminal. Regular network setup will not start until
this timer expires.
Reboot Device is the number of minutes the network can be down until unit will reboot
the network device (if assigned to a terminal). Reboot means turning off Network Device
output and then turning it back on.
4.3.2.
Reboot Delay is how long the network device will stay off on a reboot request before
turning it back on again.
Serial Ports
Port properties are the same for all ports except where noted.
User defines the user of the port. Default is Seresco which means the port is opened for
inbound traffic using the Seresco protocol. Other users are other protocols like LON and
Modbus as well as 3&4 compressor slave board communication.
Baud Rate, Databits and Parity defines your common serial port configuration
parameters.
Flow Control defines if hardware flow control should be used. Can only be configured
for the RS-232 port (port B).
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Echo Test defines if we will do an echo test every time we transmit data over the port.
Normally all data should be echoed back and therefore adding the echo test enable us to
have one more test to ensure data was transmitted with no errors. However, if there is a
minor hardware problem with the port chip, this will cause the port not to work at all.
Disabling the echo test might enable us to still use the port even with the hardware error.
Reply Delay defines for how long we will wait for a reply message before considering it
a communication fault.
4.3.3.
WebSentry
These properties controls WebSentry connection.
Set Enabled to No to disable WebSentry. You can do this if you temporarily want to
disable WebSentry connections. Also you should do this if a unit is not connected to the
Internet to avoid unnecessary attempts trying to detect a physical network link.
IP is the WebSentry server IP address. Use this property to configure the IP address or to
see what it is if DNS is enabled.
Port is the WebSentry port to connect to. This is configurable in case the port will change
in the future.
Comm Interval is how often the system will try to connect to the WebSentry server
between disconnects.
Comm Segment is how often the system will try to connect to the WebSentry server
between disconnects when we can not transmit all non-sent data in one session.
Stay Alive is how long the TCP connection will stay active from the last time a message
was received from the WebSentry server. Normally the WebSentry server should
disconnect before this time.
4.3.4.
BACnet
These properties controls BACnet connections and are only available if the
CommandCenter has been loaded with BACnet support.
Set Enabled to Yes to enabled BACnet. It is disabled by default.
Set Interface to BACnet interface type. Currently only Ehernet and IP is supported.
Use Device ID to set a unique device ID for unit on the BACnet network.
Port can be used to change the default port setting.
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The Heartbeat timer is used when BACnet interface is controlling some sensors. If no
message is received within this time, unit will rollback to system installed sensors. Setting
timer to 0 means that timer will not be used.
4.3.5.
Modbus
Use these properties to configure Modbus communication.
4.3.6.
LON
Use these properties to configure LON-Modbus gateway communication.
Set Enabled to ReadWrite to enable LON for read and write support. Set it to ReadOnly
to only let LON interface read data from unit (no changes allowed).
Use Interface to define which serial port to use for gateway communication.
Refresh Rate defines how often unit will check gateway for changed data.
4.4.
4.4.1.
Inputs/Outputs
Sensor Type
The sensor types controls how an input signal is translated into a value. Note that some
sensors that are available under sensor calibration are not available under sensor types.
These are temperature sensors for which there are no other sensor type that can be used
except Thrm.
The following sensor types are available:
• Thrm, thermistor sensor to be used for all temperature sensors.
• GSRA, Greystone return air sensor.
• GSRH, Greystone RH sensor.
• RH, General RH sensor.
• SG145, Saginomiya transducer, max 145 psi.
• SG200, Saginomiya transducer, max 200 psi.
• SG435, Saginomiya transducer, max 435 psi.
• SG500, Saginomiya transducer, max 500 psi.
• JC100, Johnson Controls transducer, max 100 psi.
• JC500, Johnson Controls transducer, max 500 psi.
• BMS, Building Management System controlled sensor.
• Calc, Calculated sensor.
4.4.2.
Sensor Usage
The sensor usage option determines how a sensor is being used.
There are four values that can be set.
None will disable sensor. It will not be used for control and will not be displayed on
sensor screen.
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Dflt is the default setting for most sensors. It means that that sensor will be used as
determined by the system. For sensors used for control, sensor will used both for control
and it will also be displayed on sensor screen.
Set sensor to View to disable sensor for control but still have it displayed on sensor
screen.
Set sensor to Ctrl to not show it on sensor screen but still have it enabled for control.
4.4.3.
Sensor Calibration
All sensor calibration values are changed the same way. You use
the up and down arrow to change the value to a few steps above or
below 0.
4.4.4.
AO Polarity
These options are used to set the polarity of the analog outputs. 0V means that device is
off or closed at 0 volts. 10V means that device is off or closed at 10 volts.
4.4.5.
Digital Inputs
These options are used to enable/disable some digital inputs. Several of them are optional
inputs that can be used to control certain components and features of the system.
4.4.6.
Sample Rates
The AI Samples and AI Sample Rate properties are used to fine tune the way analog
inputs are read and translated into sensor readings. A sensor reading is the average of all
read samples.
Refresh Sens property sets how often sensors will be read. Sensor reading will also be
generated when there is a change in the sensor reading. Refreshing sensors on a regular
basis prevents us from getting stuck with no sensor readings for a long time when the
system is stable.
The DI Samples and DI Sample Rate properties are used to fine tune the way digital
inputs are read and translated into alarms or other inputs. A digital input will signal a state
change when all samples are the same and are different from current saved state.
4.4.7.
5.
Assignments
These settings are used to assign an input or output signal to a physical input/output on
the board. The internal input/output id is being used to reference the physical
input/output. A wiring diagram is needed to determine the board terminal.
Service
To reach these settings you need to enter a service password.
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5.1.
Force Demands
Use Force Demands to test the full functionality of the exhaust fans. This feature simulates
demands from higher level control when unit is running in normal mode.
To use this feature you first have to enable it using the Enabled option. When setting Enabled to
Yes, all contacts are reset followed by starting the main Blower.
It is highly recommended not to use Force Contacts when using Force Demands. Especially
compressor related contacts.
Ventilation demand is changed by either increasing or reducing a demand. Select demand and
press up button to increase demand or down button to increase demand.
The Ventilation demand will show the current exhaust level in percentage of full capacity.
Use Occupied option to bring exhaust fans into unoccupied mode or occupied mode.
5.2.
Force Contacts
Force Contacts is used to test all the Analog and Digital Outputs. This overrides any internal
control of corresponding features and is just a way to physically test that a contact is working.
Selecting Reset All will reset all contacts back to the Off position.
5.3.
5.3.1.
Network
Ping
The ping feature is used to test the IP network.
To use ping, set the ping address and then select start. The first result line shows the IP addresses
you are pinging from (units IP address) and the second line will show 4 time values in
milliseconds.
Ping will send 4 messages to specified address and measure in milliseconds how long it will take
to get a reply. If no reply within 5 seconds the result will show Fail for that particular ping
request.
5.3.2.
5.4.
Console
The console is currently only used to monitor serial port messages. Select the serial port to
monitor by using the arrows keys. Select 1 to start monitoring. To stop/pause messages, you can
press key 2 anytime. Press Enter to clear the screen. Select back top stop console or to go back
and select another serial port.
Clear Alarm Log
Selecting Clear Alarm Log will display a confirmation screen where you have to confirm that
you want to clear the alarm log. Pressing 2 or the Back button will cancel this request.
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5.5.
Clear All Logs
Even though you only can look at the alarm log from the control panel, there are several other
logs used as well. These logs can be read using WebSentry if the unit is connected to Internet.
Use Clear All Logs to clear all the logs and not just the alarm log.
5.6.
Commission
When control board initially is configured loaded with the latest control software, unit is
prepared to make it safe and easy to use when testing unit before delivery to customer. When test
completed, the Tested option is changed to Yes and can never be changed back again.
When unit has been tested, the compressor Enabled property will be changed to No.
When Commissioned option still is set to No, unit will start up in service mode. It is not possible
to start the unit in Normal Mode. The blower can be started anytime but to enable the
compressors and to be able to change the Commissioned option, a factory password is required.
When changing Commissioned to Yes, all the logs will be cleared and the unit will do a system
restart. Now at startup you will see the normal startup screen with 2 selections, Normal Mode
and Service Mode.
The Commissioned option can be changed back to No if needed.
G - NV Series CommandCenter Operation
Page 21
10/6/2011
Section H - Routine Maintenance (NV Series)
Issue Date : 2011-10-06
Routine Maintenance
WARNING Disconnect all electrical power, including remote disconnect, and discharge all
energy storing devices before servicing. Follow proper lockout procedures to ensure the power cannot be
accidentally energized. Failure to follow provided safety warnings and labels could result in serious injury
or death.
WARNING When it is necessary to work with live electrical components, have a licenced
electrician or other qualified persons perform the required maintenance.
WARNING Danger or moving mechanical parts, high voltage power, elevated pressure and
temperature ! When performing maintenance activities, lock out the unit to prevent accidental start-up.
When service is required, call a qualified refrigeration mechanic.
Routine Maintenance Checklist
Seresco Technologies Inc.'s products are built for dependable and safe operation with minimum maintenance. Periodic
maintenance is required, however, to ensure continuous safety and maximum operating efficiency. Suggested maintenance
operations are listed in the table below with the recommended service intervals. Please note that these are general guidelines
and should be adjusted accordingly to match facility operating conditions.
Table 1. Routine Maintenance Requirements
Frequency
Weekly
Monthly
Maintenance Operation
Observe unit weekly for any change in running condition and unusual noise
Clean or replace air filters if clogged or dirty
Verify that all set-points are correctly programmed as specified by the facility operator
Inspect and clean drain pans
Tighten electrical connections if required
Check and tighten, if required, sensor mounts
Quarterly
Inspect coils for dirt build-up
Check that the P-trap is primed (filled with water). It is good practice to to pour some water into
the drain pan to ensure that the P-trap is primed and operational
Check and lubricate motor bearings. Refer to the motor manufacturer's instructions
Check outdoor air louvres for accumulation of dust and clean as required
H-1
Section H - Routine Maintenance (NV Series)
Issue Date : 2011-10-06
Inspect the unit casing for corrosion. If damage is found, clean and repaint the affected surface
with a rust-resistant primer
Clean the fan wheel(s) and motor shaft(s)
Inspect and clean drain pans
Check damper operation
Yearly
Inspect electrical components, wiring and insulation
Rotate the fan wheel(s) and check for obstructions and rubbing
Lubricate motors as directed by motor manufacturer
Check gasket condition on all doors to ensure an airtight seal
Check for loose external or internal parts, paying careful attention external components
Check bolts on motor mounts, unit bases and coils and tighten if required
Component Maintenance
Filters
Replace filters when dirty. Check filters located in main filter wall, outside air intake and exhaust fan opening. Filters should
slide out of their tracks without difficulty. Replace with filters of equivalent size and rating. See section Z - Annex for filter
sizes and quantities.
Drain Pans
WARNING Hazardous chemicals ! Cleaning agents can be highly acidic or alkaline. Handle all
chemicals carefully and use appropriate personal protective equipment (PPE). Refer to the cleaning agent
manufacturer's Materials Safety Data Sheet (MSDS) for safety and handling information. Failure to follow
all safety instructions could result in serious injury or death.
Note : Do not walk on the drain pans. Doing so will cause damage and impair drainage.
To clean drain pans:
H-2
1.
Disconnect all electrical power to the unit
2.
Remove any standing water
3.
Scrape solid foreign material off of the drain pan and vacuum to remove particulate matter
4.
Thoroughly clean any contaminated area(s) with a mild bleach and water solution or an EPA approved
Section H - Routine Maintenance (NV Series)
Issue Date : 2011-10-06
sanitizer designed for HVAC use. Immediately rinse with fresh water to prevent corrosion
5.
Allow to dry completely before putting the unit back into service. Dispose of all contaminated
materials
Impellers / Fans
To clean fan blades:
1.
Disconnect all electrical power to the unit
2.
Scrape solid foreign material off of the fan blades and vacuum to remove particulate matter
3.
Thoroughly clean any contaminated area(s) with a mild bleach and water solution or an EPA approved
sanitizer designed for HVAC use. Immediately rinse with fresh water to prevent corrosion
4.
Allow to dry completely before putting the unit back into service. Dispose of all contaminated
materials
Motors
Inspect fan motors periodically for excessive vibration or temperature. For bearing lubrication and other maintenance
activities, see manufacturer's literature provided in the appendix.
Coils
WARNING Hazardous pressures ! Coils containing refrigerant under pressure must not be
cleaned using a solution over 150 ºF. Failure to follow these safety precautions could result in coil bursting,
which could result in serious injury or death.
To clean coils:
1.
Disconnect all electrical power to the unit
2.
Wearing the appropriate personal protective equipment (PPE), use a soft brush to remove loose debris
from the coil
3.
Install a block-off to prevent spray from going through the coil and into a dry section of the unit and /
or system ductwork
4.
Mix a high quality coil cleaning detergent with water according to the manufacturer's instructions
5.
Place the mixed solution in a garden pump-up sprayer or high-pressure sprayer. If a high-pressure
sprayer is to be used:
H-3
Section H - Routine Maintenance (NV Series)
Issue Date : 2011-10-06
a) Maintain minimum nozzle spray angle of 15 degrees
b) Spray perpendicular to the coil face
c)
keep the nozzle at least 6 inches from the coil
d) Do not exceed 60 psi
6.
Spray the leaving side of the coil first, then the entering air side
7.
Thoroughly rinse both sides of the coil and the drain pan with cool, clean water
8.
Straighten any coil fins that have been bent during the cleaning process
9.
Confirm the drain line is clear
10. Replace all panels and parts and restore electrical power to the unit
11. Dispose of all contaminated materials
Insulation
Note : Microbial growth ! Wet interior insulation can become an amplification site for microbial growth
(mold), which may cause odours and damage to the equipment and building materials. If there is evidence
of microbial growth on the interior insulation, the insulation should be removed and replaced prior to
operating the system.
Accumulated dirt and other organic matter exposed to water or extended periods of high relative humidity (60 percent or
higher) can support microbial growth, which must be removed to prevent the unit from becoming a contaminant source. If
evidence of contamination exists, determine and eliminate the cause, remove the contamination and sanitize the affected
area.
H-4
Issue Date : 2011-10-06
Section H - Routine Maintenance (NV Series)
Outdoor Air Balancing
The amount of outdoor air introduced into the unit varies by season. Seresco Technologies Inc. provides manual balancing
dampers with all outdoor air equipped units. Even if a unit mounted motorized air damper is installed, the manual damper
will also be installed. There are two types of manual dampers depending on the size of the unit.
NE/NP-004 to -016 and NE/NP-2xx Series
Note that the Outdoor Air filter box contains two perforated sliding plates as shown in Figure H-1. Adjust the manual
damper by turning the black knob to slide one plate along the other. Align the holes for maximum air flow or misalign the
holes to block or dampen the airflow.
Figure H-2. Outdoor Air Filter Box
For NE/NP/NV-018 to NE/NP/NV-120
To adjust the outdoor air balance, first remove the filters. The manual damper consists of two perforated plates, one of which
slides on top of the other. To adjust the air balance loosen all the screws and slide the plate to obtain the desired setting. Retighten all the screws.
H-5
Section H - Routine Maintenance (NV Series)
Figure H-3. Outdoor Air Filter Box
Figure H-4. Outdoor Air Tightening Screw (highlighted)
H-6
Issue Date : 2011-10-06
Section X - Troubleshooting
Issue Date : 2011-09-20
Troubleshooting
This section is intended to be used as a diagnostic aid only. For detailed repair procedures, contact Seresco Technologies
Inc.'s service department.
Two user-friendly service tools are critical in troubleshooting any issues with Seresco's dehumidification systems: the
WebSentry remote monitoring software and automated system alarm logs. WebSentry remote monitoring software allows
the collection of comprehensive unit performance data and space conditions via the Internet. This option is default on all
units with CommandCenter controls and has proven to be an extremely effective service tool. To function correctly, this
requires the unit to be connected to a local network with Internet access. System Alarm Logs detail information on alarm
situations, including the type of alarm, faults and time to help service technicians narrow down possible cause(s) of the
problem(s).
Troubleshooting Steps
1.
Collect information from unit owner/maintenance team about problem(s)
2.
Refer to the provided Installation, Operation and Maintenance manual and the unit label for additional
information
3.
Perform a basic visual inspection of the unit
4.
Check the System Alarm Log for the latest alarm(s)
CAUTION If the unit is powered down: before powering up the system again, ensure that it is safe
to do so.
5.
Refer to the list of common problems provided below for probable causes and suggested solutions
6.
If you require further assistance, please feel free to contact Seresco's Service and Technical Support (STS)
department
Contacting Seresco Service and Technical Support (STS)
The next availible service technician can be reached by phone at (613)-741-3603, followed by 2, or by e-mail at
[email protected]. When contacting Seresco STS, please have the following information on hand:
−
Your name
−
Service company name
−
Phone number
−
Seresco unit serial number (8 digit number on the unit label i.e. 11011800)
X-1
Section X - Troubleshooting
Issue Date : 2011-09-20
WebSentry Connection Troubleshooting Guide
Ethernet cable connected and operating
First thing to check is that the Ethernet cable has been hooked up properly and is operating normally. Use the LED’s by the
Ethernet socket to verify this. The LED’s are the two white square components on the mini board with the Ethernet socket.
The one closest to the socket should be solid green and indicates a solid physical connection. Unplug cable at the unit or at
the other end and this LED will go blank.
If cable is connected at both end and the LED still does not lit up, it is very possible the Ethernet socket itself is faulty.
Connecting a network cable between a laptop and unit can determine that indeed the Ethernet socket is faulty and that there
is not a faulty router port or faulty cable.
The second LED is yellow and will blink when there is communication.
Firewall settings
The unit will try to connect to the WebSentry server once a minute using port 1030. Server name is websentry.seresco.net.
Use ping to determine IP address associated with this IP address if this is needed for any firewall settings.
If network has a firewall, port 1030 must be open for communication or at least for the IP assigned to unit or the MAC
address for the unit or to/from the Seresco domain name or server IP.
The MAC address can be found under System Info using the local keypad. ‘*’ translates to 00:90:C2 so that if MAC shows
*:D1:2A:49 the full MAC address is 00:90:C2:D1:2A:49.
Checking network communication status
Check status of network communication from the local keypad. From main screen select Main Menu (1) - System (3) System Status (5) - Network (4).
TCP/IP should be saying Up. If it says PendingUp, there is a problem with establishing a physical connection. Network
cables and router/switch needs to be checked. Ensure light over port where unit is connected is lit up.
WebSentry will say Idle when waiting to connect to server (connects once a minute). When connected you will either see
Receive or Send. If it shows Connecting for several seconds it means there is a problem establishing a connection to the
server. Usually it will toggle between Idle and Connecting when a proper connection is not established. Check TCP/IP and
WebSentry configuration settings.
X-2
Issue Date : 2011-09-20
Section X - Troubleshooting
Checking TCP/IP configuration settings
Unit can be configured for dynamic or static IP. From main screen select Main Menu (1) - Factory Settings (5) - Network (5)
- TCP/IP (1). If asked for a password at Factory Settings selection, enter 813.
DHCP set to Yes is for dynamic IP and if set to no, unit is configured for Static IP.
Dynamic IP
You should see an IP and Mask assigned (* means 255). This is assigned by the router to which the unit is connected. On
second page you should also see IP's assigned to GW (Gateway) and DNS.
If any of these IP’s are not assigned properly (showing 0.0.0.0 for instance), there is a problem with the router assigning IP
info to the unit.
Static IP
IP, Mask, GW and DNS all have to be configured correctly or unit will not be able to communicate with the WebSentry
server. This information should be known by the IT group managing the local network.
Check WebSentry configuration settings
By default the unit is configured to use DNS (Domain Name Server) to translate the Seresco domain name to the
appropriate WebSentry IP address. Before software version 4.8.0, domain name www.seresco.net was used. Starting from
version 4.8.0, domain name websentry.seresco.net is used.
If the IP is changing between an IP address and 0.0.0.0, there is a problem with the domain name lookup. In this case you
can try to configure a static IP for the WebSentry server.
Change Use DNS to No and then change the IP address to IP of websentry.seresco.net (currently 97.74.200.218).
Testing Internet access from unit
Unit has a Ping feature that can be used to test that unit can connect to any IP address on the local network as well as to any
IP over Internet.
To use the Ping feature you have to start the unit in Service Mode. From main screen select Main Menu (1) - System (3) System Restart (3) and then press Yes (1) to confirm.
When unit starts up you will have a selection menu. Select Service (2).
X-3
Section X - Troubleshooting
Issue Date : 2011-09-20
To access the Ping feature, select Main Menu (1) – Service (6) – Network (3) – Ping (1). If asked for a password at Service
selection, enter 813.
To test connection to WebSentry server, make sure IP (selection 1) is set to 97.74.200.218. Press 2 to start Ping request.
The 3rd line shows the current IP address assigned to the unit. The 4th line will either have 4 time values or the text Fail (up
to 4 times). The time values indicate number of milliseconds for Ping message to go to WebSentry server and back.
Testing Internet access and WebSentry access from unit Ethernet cable
A simple test you can do to make sure there is Internet access from the Ethernet cable connected to our unit is to connect
this cable into a laptop and accessing any web site using a web browser.
If unit is configured for static IP, you should configure the laptop with the exact same TCP/IP configuration. How this is
done is not covered in this document.
IMPORTANT! Make sure WiFi connection is disabled when testing Ethernet cable.
A secondary test to ensure you can communicate with the Seresco WebSentry server is to use the Telnet command to
establish a connection to the server.
Open up the Command Prompt window. Enter the command:
telnet 97.74.200.218 1030
You should now see a blank screen with a prompt. Hit any two characters. The text Seresco WebSentry should now be
displayed followed by Connection to host lost. This verifies that you can open up a connection to the port used by the
WebSentry server and that this port is not blocked by any firewall.
If the connection failed it most likely is a firewall issue. Port 1030 must be open for communication or at least for the IP
assigned to the Seresco unit.
Contact Factory
If everything in this document has been tested and everything indicates that the communication should be working, we are
dealing with an unknown fault. Contact Seresco for further advice.
X-4
Issue Date : 2011-09-30
Section Y - Warranty
Warranty
General Policy
This warranty applies to the original equipment owner and is not transferable. Seresco Technologies Inc.
warrants as set forth and for the time periods shown below that it will furnish, through a Seresco Technologies
Inc. authorized installing contractor or service organization, a new or rebuilt part for a factory installed part
which has failed because of defect in workmanship or material.
Warranty Void Unless Registered
Warranty is void unless, upon start-up of the unit, the “Warranty Registration and Start-up Report” is
completed and sent to the factory within one week of initial start-up. This report will also register the
compressor warranty with the compressor manufacturer.
Initial 90-day Warranty
During the first 90 days from initial start-up and prior to the completion of the 24th month from date of
shipment, whichever comes first and subject to prior written approval from the factory, Seresco Technologies
Inc. will provide and/or reimburse the required labour, materials, and shipping and handling costs incurred in
the replacement or repair of a factory installed defective part. Only the labour required to replace the defective
part is warrantied – travel time, diagnostic time, per diems, truck charges, etc. are not covered under this
warranty.
WebSentry Conditional One Year Extended Labour Warranty
The factory labour warranty shall be extended for a total of 12 months from initial start-up and prior to the
completion of the 24th month from date of shipment, whichever comes first and subject to prior written
approval from the factory. The provided equipment must be connected and communicating to Seresco's
WebSentry online control and monitoring service for the entire term of the warranty extension. Seresco
Technologies Inc. will provide and/or reimburse the required labour, materials, and shipping and handling
costs incurred in the replacement or repair of a factory installed defective part. Only the labour required to
replace the defective part is warrantied – travel time, diagnostic time, per diems, truck charges, etc. are not
covered under this warranty.
Two Year Parts Warranty
If any factory installed part supplied by Seresco Technologies Inc. fails because of a defect in workmanship or
material prior to the completion of the 24th month from date of shipment, Seresco Technologies Inc. will
Y-1
Section Y - Warranty
Issue Date : 2011-09-30
furnish a new or rebuilt part F.O.B. factory. No labour reimbursement will be made for expenses incurred in
making field adjustments or parts replacement outside the Initial 90-day Warranty. Seresco Technologies Inc.
reserves the right to have the defective part returned to the factory in order to determine the warranty
applicability. Parts shipping and handling costs (to and from the factory) are not covered outside of the Initial
90-day Warranty.
Replacement Part Warranty
If a replacement part provided by Seresco Technologies Inc. under this warranty fails due to a material defect
prior to the end of the Two Year Parts Warranty (or the end of the extended warranty period if applicable) or 12
months from date of the replacement part shipment, whichever comes first, Seresco Technologies Inc. will
furnish a new or rebuilt part F.O.B. factory.
Applicability
This warranty is applicable only to products that are purchased and installed in the United States and Canada.
This warranty is NOT applicable to :
1.
Products that have become defective or damaged as a result of the use of a contaminated water
circuit or operation at abnormal water temperatures and/or flow rates
2.
Parts that wear out due to normal usage, such as air filters, belts and fuses. 2. Refrigerant lost during
the parts warranty will be reimbursed in accordance to the current market price of refrigerant at the
time of repair. Seresco Technologies Inc. will not be responsible for refrigerant lost from the system
due to improperly installed contractor piping to the remote outdoor air cooled condenser.
3.
Refrigerant coils that corrode due to improperly balanced pool chemistry or corrosive air quality.
4.
Components that have been relocated from their original placement at the factory.
5.
Any portion of the system not supplied by Seresco Technologies Inc.
6.
Products on which the model and/or serial number plates have been removed or defaced.
7.
Products which have become defective or damaged as a result of unauthorized opening of
refrigeration circuit, improper wiring, electrical supply characteristics, poor maintenance, accidents,
transportation, misuse, abuse, fire, flood, alteration and/or misapplication of the product.
8.
Products not installed, operated and maintained as per Seresco Technologies Inc. Owner’s Manual.
9.
Products on which payment is in default.
Limitations
This warranty is given in lieu of all other warranties. Anything in the warranty notwithstanding, any implied
warranties of fitness for particular purpose and merchantability shall be limited to the duration of the express
warranty. Manufacturer expressly disclaims and excludes any liability for consequential or incidental damage
Y-2
Issue Date : 2011-09-30
Section Y - Warranty
for breach of any express or implied warranty.
Where a jurisdiction does not allow limitations or exclusions in a warranty, the foregoing limitations and
exclusions shall not apply to the extent of the legislation, however, in such case the balance of the above
warranty shall remain in full force and effect.
This warranty gives specific legal rights. Other rights may vary according to local legislation.
Force Majeure
Seresco Technologies Inc. will not be liable for delay or failure to provide warranty service due to government
restrictions or restraints, war, strikes, material shortages, acts of God or other causes beyond Seresco
Technologies Inc. control.
Optional Five Year Compressor Warranty
This extended warranty must be purchased before the shipment of the unit.
Seresco Technologies Inc. will provide a replacement compressor for 60 months from the date of shipment
provided the factory installed compressor fails as a result of manufacturing defect and is returned to the factory
with transportation prepaid. This extended compressor warranty is subject to all the terms of the standard
Seresco Technologies Inc. warranty but applied to the compressor only.
No charges attributed to the replacement of a component, except as detailed in above Initial 90-day Warranty,
will be allowed unless specifically granted in writing beforehand by Seresco Technologies Inc.
Optional Five Year Airside Coil Warranty
This extended warranty must be purchased before the shipment of the unit.
Seresco Technologies Inc. will provide a replacement Airside Coil for 60 months from the date of shipment
provided the failed coil is returned to the factory with transportation prepaid. This extended coil warranty is
subject to all the terms of the standard NE Series warranty but applied to the coil only.
No charges attributed to the replacement of a component, except as detailed in above Initial 90-day Warranty,
will be allowed unless specifically granted in writing beforehand by Seresco Technologies Inc.
This warranty is contingent to the proper maintenance of pool water chemistry including a pH of between 7.2
and 7.6 free chlorine not exceeding 2.0 ppm and combined chlorine maintained at less than 0.3 ppm. These
Y-3
Section Y - Warranty
Issue Date : 2011-09-30
parameters are to be measured and recorded daily and be available for review upon request.
Optional 10 Year Airside Coil Warranty
This extended warranty must be purchased before the shipment of the unit.
Seresco Technologies Inc. will provide a replacement Airside Coil for 120 months from the date of shipment
provided the failed coil is returned to the factory with transportation prepaid. This extended coil warranty is
subject to all the terms of the standard NE Series warranty but applied to the coil only.
No charges attributed to the replacement of a component, except as detailed in above Initial 90-day Warranty,
will be allowed unless specifically granted in writing beforehand by Seresco Technologies Inc.
This warranty is contingent to the proper maintenance of pool water chemistry including a pH of between 7.2
and 7.6 free chlorine not exceeding 2.0 ppm and combined chlorine maintained at less than 0.3 ppm. These
parameters are to be measured and recorded daily and be available for review upon request.
Optional Five Year Driveline Warranty
This extended warranty must be purchased before the shipment of the unit.
Seresco Technologies Inc. will provide a replacement part for the following components:
Supply fan motor
Supply fan motor starter
Exhaust fan motor
Exhaust fan motor starter
Pool water heater solenoid valves & valve coils
Liquid expansion solenoid valves & valve coils
Air-cooled condenser solenoid valves & valve coils
Blowers
Driveline warranty exists for 60 months from the date of shipment provided the factory installed component
fails as a result of manufacturing defect and is returned to the factory with transportation prepaid. This
extended driveline warranty is subject to all the terms of the standard Seresco Technologies Inc. warranty but
applied to the listed parts only.
No charges attributed to the replacement of a component will be allowed unless specifically granted in writing
beforehand by Seresco Technologies Inc.
Y-4
Issue Date : 2011-09-30
Section Z - Annex
Unit Component Specifications
&
Component Service Sheets
Z-1
Z - Startup Report
Issue Date : 2011-09-30
Startup Report - Seresco Technologies Inc.
Project Name
NE Series Model
Location
Serial Number
Site Contact/Tel:
Seresco Rep.
Unit Visual Inspection
Check
Comments
Supply air blowing on exterior doors and windows?
No supply-return air short-circuiting?
Outdoor air connected to Seresco unit?
Exhaust fan installed and operating, away from intake?
Vapor Barrier installed?
Condensate P-Trap installed and filled?
Condensate line tested?
Pool Water piping properly installed?
Auxiliary pool water circulating pump installed?
Pool water flow to spec?
OACC or Dry Cooler installed and wired properly?
Nameplate voltages verified?
Main disconnect installed?
Wiring connections checked & tightened?
Control wiring to aux pool heater installed?
Floor drain in mechanical room?
Chemicals stored in separate ventilated room?
Air balance report on file?
List other external controlled components
WebSentry connected?
Blowers, compressors rotation checked?
Adequate service access provided?
Unit’s leveled and vibration isolated?
Flex connectors used at both duct connections?
What type of refrigerant is used?
** TO VALIDATE WARRANTY FILL OUT AND FAX to 1-613-741-3375 **
1 of 4
Z - Startup Report
Issue Date : 2011-09-30
Unit Electrical Data
L1 – L2
L1 – L3
L2 – L3
Nameplate
Unit Voltage (V)
Transformer secondary voltage (V)
Compressor 1 (A)
Compressor 2 (A)
Main Blower 1 (A)
Main Blower 2 (A)
Exhaust Blower 1 (A)
Exhaust Blower2 (A)
Purge Blower 1 (A)
Purge Blower 2 (A)
OACC Motor 1 (A)
OACC Motor 2 (A)
OACC Motor 3 (A)
OACC Motor 4 (A)
Heat Recovery Pump (A)
Hot Water Pump (A)
Hot Water Pump 2(A)
NOTE: Put ALL additional info/comments into Notes section.
Outdoor Air Condensing / Cooling Unit inspection
Check
Comments/Data
OACC or dry cooler located how feet above/below/level with
Seresco Unit?
Oil traps installed for OACC?
Model number of condenser
Field charge added in pounds and refrigerant type
Fluid GPM
Glycol %
Glycol stabilizers added?
Distance from Seresco Unit to OACC or dry cooler (one-way
line length), ft
Hot gas line size (in)
Liquid line size (in)
Pipe size to dry cooler (in)
2 of 4
For tech support call: 1-770-457-3392 ext.2#
OR 1-613-741-3603 ext.4#
Z - Startup Report
Issue Date : 2011-09-30
Fluid Temperature entering main unit (F)
Fluid Temperature leaving main unit (F)
Piping and valves installed per spec?
Unit Operating Data and Configurations
Sensor
Operating Data
Reheat
Reheat +
Pool heat
A/C
Unit Configuration
Setpoints
Value
A/C +
Pool heat
Return Air (F)
Return Air (F)
Return Air (% RH)
Return Air (RH)
Supply Air (F)
Pool 1 (F)
Pool 1 In (F)
Pool 2 (F)
Pool 1 Out (F)
Purge (F)
Pool 2 In (F)
HR (F)
Pool 2 Out (F)
Economizer (F)
Outdoor Air (F)
Comp 1 HP (psi)
Air Heating Type
Comp 1 LP (psi)
Clock Set?
Comp 1 Suction (F)
Board #
Comp 1 Discharge (F)
MAC address
Evap 1 (F)
IP address
Superheat 1 (F)
Comp 2 HP (psi)
BACNET?
Comp 2 LP (psi)
LON?
Comp 2 Suction (F)
MODBUS?
Comp 2 Discharge (F)
Evap 2 (F)
Superheat 2 (F)
Exhaust (F)
Reheat (F)
NOTE: Check/verify superheat is
within 18 – 22 F margin; refer to
Pressure -Temperature chart for proper
refrigerant. Adjust if required.
T/B Sight Glasess1
T/B Sight Glasses 2
Moisture Indicator 1
NOTE: For Receiver Sight glasses:
T(top)/B(bottom) make note whether
ball is “UP” or “DOWN”.
Moisture Indicator 2
** TO VALIDATE WARRANTY FILL OUT AND FAX to 1-613-741-3375 **
3 of 4
Z - Startup Report
Issue Date : 2011-09-30
Startup Date
Startup Company Name
Startup Company Contact #
Startup Technician Name
Startup Technician Contact #
Notes/Comments/Info
4 of 4
For tech support call: 1-770-457-3392 ext.2#
OR 1-613-741-3603 ext.4#
Z - Startup Report
Issue Date : 2011-09-30
Startup Report - Seresco Technologies Inc.
Project Name
NE Series Model
Location
Serial Number
Site Contact/Tel:
Seresco Rep.
Unit Visual Inspection
Check
Comments
Supply air blowing on exterior doors and windows?
No supply-return air short-circuiting?
Outdoor air connected to Seresco unit?
Exhaust fan installed and operating, away from intake?
Vapor Barrier installed?
Condensate P-Trap installed and filled?
Condensate line tested?
Pool Water piping properly installed?
Auxiliary pool water circulating pump installed?
Pool water flow to spec?
OACC or Dry Cooler installed and wired properly?
Nameplate voltages verified?
Main disconnect installed?
Wiring connections checked & tightened?
Control wiring to aux pool heater installed?
Floor drain in mechanical room?
Chemicals stored in separate ventilated room?
Air balance report on file?
List other external controlled components
WebSentry connected?
Blowers, compressors rotation checked?
Adequate service access provided?
Unit’s leveled and vibration isolated?
Flex connectors used at both duct connections?
What type of refrigerant is used?
** TO VALIDATE WARRANTY FILL OUT AND FAX to 1-613-741-3375 **
1 of 4
Z - Startup Report
Issue Date : 2011-09-30
Unit Electrical Data
L1 – L2
L1 – L3
L2 – L3
Nameplate
Unit Voltage (V)
Transformer secondary voltage (V)
Compressor 1 (A)
Compressor 2 (A)
Main Blower 1 (A)
Main Blower 2 (A)
Exhaust Blower 1 (A)
Exhaust Blower2 (A)
Purge Blower 1 (A)
Purge Blower 2 (A)
OACC Motor 1 (A)
OACC Motor 2 (A)
OACC Motor 3 (A)
OACC Motor 4 (A)
Heat Recovery Pump (A)
Hot Water Pump (A)
Hot Water Pump 2(A)
NOTE: Put ALL additional info/comments into Notes section.
Outdoor Air Condensing / Cooling Unit inspection
Check
Comments/Data
OACC or dry cooler located how feet above/below/level with
Seresco Unit?
Oil traps installed for OACC?
Model number of condenser
Field charge added in pounds and refrigerant type
Fluid GPM
Glycol %
Glycol stabilizers added?
Distance from Seresco Unit to OACC or dry cooler (one-way
line length), ft
Hot gas line size (in)
Liquid line size (in)
Pipe size to dry cooler (in)
2 of 4
For tech support call: 1-770-457-3392 ext.2#
OR 1-613-741-3603 ext.4#
Z - Startup Report
Issue Date : 2011-09-30
Fluid Temperature entering main unit (F)
Fluid Temperature leaving main unit (F)
Piping and valves installed per spec?
Unit Operating Data and Configurations
Sensor
Operating Data
Reheat
Reheat +
Pool heat
A/C
Unit Configuration
Setpoints
Value
A/C +
Pool heat
Return Air (F)
Return Air (F)
Return Air (% RH)
Return Air (RH)
Supply Air (F)
Pool 1 (F)
Pool 1 In (F)
Pool 2 (F)
Pool 1 Out (F)
Purge (F)
Pool 2 In (F)
HR (F)
Pool 2 Out (F)
Economizer (F)
Outdoor Air (F)
Comp 1 HP (psi)
Air Heating Type
Comp 1 LP (psi)
Clock Set?
Comp 1 Suction (F)
Board #
Comp 1 Discharge (F)
MAC address
Evap 1 (F)
IP address
Superheat 1 (F)
Comp 2 HP (psi)
BACNET?
Comp 2 LP (psi)
LON?
Comp 2 Suction (F)
MODBUS?
Comp 2 Discharge (F)
Evap 2 (F)
Superheat 2 (F)
Exhaust (F)
Reheat (F)
NOTE: Check/verify superheat is
within 18 – 22 F margin; refer to
Pressure -Temperature chart for proper
refrigerant. Adjust if required.
T/B Sight Glasess1
T/B Sight Glasses 2
Moisture Indicator 1
NOTE: For Receiver Sight glasses:
T(top)/B(bottom) make note whether
ball is “UP” or “DOWN”.
Moisture Indicator 2
** TO VALIDATE WARRANTY FILL OUT AND FAX to 1-613-741-3375 **
3 of 4
Z - Startup Report
Issue Date : 2011-09-30
Startup Date
Startup Company Name
Startup Company Contact #
Startup Technician Name
Startup Technician Contact #
Notes/Comments/Info
4 of 4
For tech support call: 1-770-457-3392 ext.2#
OR 1-613-741-3603 ext.4#
Rotating Electrical Machines
Installation Instructions
NEMA - IEC
W Range
Totally enclosed fan-cooled (TEFC)
three-phase motors with squirrel cage
for low voltage, with antifriction bearings.
Installation & Maintenance
Introduction
Where an eyebolt is provided with the motor, this
coating is damaged, it should be made good. The
All ac induction motors are designed for long life and
should be screwed down until its shoulder is firmly
component should be cleaned and the protective
low running costs. Careful installation and mainte-
seated against the face of the stator frame to be lift-
coating reapplied. Under no circumstances should
nance will ensure that you achieve reliable operation
ed. Eyebolts are normally designed for a vertical lift.
rust be merely covered over.
and optimum efficiency. For motors with specific
duties, such as brake motors, single phase motors
For lifting lug or trunnion torques, see table below:
refer to your supplier.
Drain holes
Lifting lug bolt torques
and motors installed within hazardous areas, please
Motors of frame size 160 /254T and above have
Type
Metric
NEMA
/CSA
Bolt
dia*
Torque
drain holes fitted with drain plugs as standard.
Nm
Lbf.FT
Alternatively, the drain plugs can be provided loose
63
-
-
-
-
71
-
-
-
-
80
56
-
-
-
90
143/5T
100L
112M
182/4T
-
-
-
M12*
-
-
be vibration free. if this is not possible, it is strongly
available together with tools and equipment neces-
132S/M
213/5T
M12*
-
-
recommended that the motors be stood on thick
sary for safe working practice. If there are any safety
160M/L
254/6T
M12*
-
-
blocks of rubber or other soft material.
concerns, do not install or attempt to operate the
motor. Please contact your supplier for advice or
180M/L
284/6T
M16*
-
-
M10*
M10*
M10*
M10*
M16*
M16*
M16*
M16*
M20*
M20*
M20*
52
52
52
52
220
220
220
220
400
400
400
38
38
38
38
162
162
162
162
295
295
295
Pre-installation requirements
Warning
Handling and lifting of electric motors must only be
undertaken by authorised personnel. Full product
documentation and operating instruction must be
assistance.
Receipt
Before any motor is accepted on site, it should be
inspected carefully against the following checklist:
a) Check that the description on the
consignment note agrees with your order
specification.
200L
324T
225S
326T
225M
364T
250S
365T
250M
404T
280S
405T
280M
444T
315S
445T
315M
504Z
315L
505Z
355S/M/L 585/6/7Z
in the terminal box if specifically requested.
Bearings
To avoid static indentation, the storage area should
Where the exposure to some vibration is unavoidable, the shaft should be locked in position to avoid
static indentation of the bearings.
Shafts should be rotated by hand one quarter of a
revolution weekly.
Roller bearings may be fitted with a shaft locking
device. This should be kept in place during storage.
Grease
b) Check that the rating, speed etc are in
accordance with your requirements.
c) Check for any damage, rust, dirt, foreign
substance etc. Where an instance of
* Lifting lugs secured with bolts and nuts. High ten-
Factory-fitted bearings use a grease with a recom-
sile socket headed bolts and special square nuts
mended shelf life of two years. If stored for a longer
must be used. Aluminum frame motors should have
period the grease may need to be replaced*.
eyebolt firmly screwed down (without overtighten-
Shielded bearings have a storage life of five years
ing), to ensure that the collar is fully seated.
and a further two years operational life following
installation.
droppage or loss is evident or suspected, it may
be necessary to unpack the goods to
Where two eyebolts/lifting lugs are used with inclined
establish the full extent of the problem.
loading, the maximum safe working load quoted on
*Wash all bearing parts with a non-contaminating
Wherever possible, damage should be
the lifting arrangement must not be exceeded.
solvent. Lightly pack the bearings with grease applying a 25% fill by volume into the bearing and hous-
recorded, photographed and witnessed.
Storage
ings. Run the motor on no-load to distribute grease
Report any damage to the carriers and
If motors have to be stored before installation, pre-
and reduce losses.
your supplier as soon as possible, quoting
the motor and/or order number and
cautions should be taken to prevent deterioration:
shipping reference.
Environment
Where heaters are fitted, and the storage environ-
Depending on the site conditions, it may be neces-
ment has wide humidity and temperature variations,
it is strongly recommended they be energised.
specified, is correct. Manually turn the
sary to create a suitable stores area to hold the
motor prior to installation. Packing cases are not
shaft and check for smooth, quiet rotation.
waterproof.
Warnings should be placed on the motors to
make operatives aware of the live heaters.
Electric motors should not be transported
Motors should be stored in a dry, vibration free and
by rail, as vibration from this method of
clean area at normal ambients (-20°C to 40°C),
Insulation resistance
transport has been known to cause
unless other arrangements have been agreed.
During extended storage, a three-monthly insulation
d) Check that the direction of rotation, if
Heaters
test is recommended to avoid possible lengthy dry-
brinelling of bearings.
Where low temperature ambient storage is anticipatLifting
ing out periods when installing.
ed, special precautions should be taken with the
Eyebolts, lifting lugs and lifting trunnions supplied
type of grease, no plastic parts etc to ensure trouble-
The insulation resistance between phases and
with the motor are designed to support only the
free start-up.
between the phase and earth should be checked
and maintained above 10 Megohm.
weight of the motor, not the weight of the motor and
any ancillary equipment attached to it. Be absolutely
Motors must be stored away from corrosive or
sure that cranes, jacks, slings and lifting beams are
chemically damaging fumes. Before placing motors
capable of carrying the weight of equipment to be
into storage, machined components should be care-
If a lower reading is measured, use one of the recommended drying out methods until an acceptable
lifted safely.
fully inspected. Bearings and shafts are normally
reading is obtained. If heaters are fitted but not ener-
covered with a corrosion resistive barrier. If this
gised, they should be used in future.
1
Installation & Maintenance
Installation
overheating or undue voltage drop.
its of its design voltage and frequency.
It is the users or certified electricians reponsibility to ensure correct earthing and protection in
Cable terminations
Standard motors will operate without damage on any
voltage within the range of the nameplate voltage.
accordance with applicable national and local
All cable terminations should be tightly secured.
requirements and standards.
Mains lead terminal lugs should be in face-to-face
The supply cables must be capable of carrying the
contact with the motor lead lugs and securing nuts
full load current of the motor (see motor nameplate)
Location
and lockwashers screwed firmly over the connection.
without overheating or excessive voltage drop under
Motors must be installed with adequate access for
There should be no nuts or lockwashers fitted
starting conditions.
routine maintenance. A minimum of 0.75m of work-
between the mains and motor lugs.
Grounding
ing space around the motor is recommended, particular attention at the fan inlet (50mm) is necessary to
Wiring should be carried out or checked by a quali-
All motors fitted with an grounding terminal, in or
facilitate airflow. Ensure that there is sufficient free
fied electrician and equipment must be earthed in
adjacent to the terminal box to enable connection to
area in front of the air intake.
accordance with current regulations. The equipment
an effective earthing bond. The terminal is designed
Where several motors are installed in close proximi-
must be correctly fused and isolated. All covers must
be in position prior to running.
for connecting the correct size of copper earth connector. If a different material is to be used, please
refer to your supplier.
ty, care must be taken to ensure that there is no recirculation of exhausted warm air, as this will reduce
All fixing bolts and electrical connections should be
the effectiveness of the cooling system.
checked and tightened if necessary after 100-200
An earthing bond should not be terminated
hours of operation.
under the motor fixture bolts or terminal cover
screws. The ground lead could be overlooked
Foundations must be solid, rigid, level and where
possible free from any external vibration.
Warning
on reconnection after maintenance.
Isolate power supply to motor before commencing
Mechanical
any routine cleaning or maintenance work.
Auxiliary electrical items
Where auxiliaries are fitted, the characteristics
Drain holes
Prior to installation, remove drain plugs if fitted. If
Drying out procedures
should be checked. Example: RTDs (Resistance
any water has accumulated, the integrity of all gaskets, sealants etc should be checked. Drain plugs
It is preferable to dismantle the motor to the point
where the rotor is removed. This is not essential but
Temperature Detectors), should have their resistances checked against manufacturer’s figures.
should be put back into place after draining.
the drying out process will take longer in the assembled state. The temperature of the windings and the
Auxiliaries should be checked for continuity prior to
Alignment
insulation resistance should be monitored at regular
connection to the control circuitry.
When the application calls for direct coupling, the
intervals. On initial application of heat, the insulation
shafts must be correctly aligned in all three planes.
resistance will drop quickly and then start to rise
Do not apply more than 6V across the thermistor for
Bad alignment can be a major source of noise and
slowly until level. On discontinuation of the drying
continuity check.
vibration.
process, a further rise in resistance will occur.
Allowance must be made for shaft end-float and
There are several methods which can be used:
Ensure all control gear and associated metering/pro-
thermal expansion in both axial and vertical planes.
1) Place the motor in a warm (typically 40°C),
tection circuits have been checked fully.
Control gear
It is preferable to use flexible drive couplings.
dry airstream (fan or convector heater) or
in a warm oven with a temperature not
It is imperative that any overload trip and emer-
Motors fitted with angular contact or duplex bear-
exceeding 80°C. This method is preferred if the
gency shutdown circuits are working correctly
motor is dismantled.
before the motor is energised. All covers must
ings, must always be run loaded.
2) Connect the motor to a low voltage* three
be in position.
Slide rails and slide bases
phase supply and inject a current not
Slide rails and bases are available for all motors in
exceeding 50% of the full load current into
Where a motor is fitted with a separately driven fan
the product range to provide adjustable mounting.
the stator winding (*approximately 10% of
unit, the interlocks and thermal overload protection
Fabricated steel rails and bases are the standard
the line voltage). If this is carried out on an
circuits must be operative.
offer as they are suitable for all relevant mounting
assembled motor, it is possible though
arrangements.
unlikely that the motor will turn. If so, the
Rotation
rotor should be locked in position.
Before coupling the motor to the drive, run the motor
Installation:
1) They must be installed on a flat surface.
3) Connect two phases in parallel, and the
third in series. Apply a low voltage ac or dc
2) They must have a secure location.
suply up to a maximum of 50% of full load
3) Drive and driven shaft must be parallel.
current. The stator winding temperature must not
Electrical connection
Connection diagrams
The connection diagram is shown on the leaflet
enclosed in the motor terminal box or diagram inside
the terminal box lid and provides supply details and
All covers must be in place.
be allowed to exceed 80°C. In practice, the frame
To reverse the direction of rotation, interchange any
should not be hot to the touch, to guard against
two incoming supply leads.
internal overheating and consequent damage to
the insulation.
4) Where heaters are fitted, these can be
energised.
the required winding connection. The cables used
should be capable of carrying the full load current of
Supply
the motor (see motor nameplate), without
It is important that a motor is operated within the lim-
2
briefly to check rotation.
Installation & Maintenance
Starting
not generally recommended to use two pole motors
the correct position (if in doubt, contact
Motors are rated by the output required, the number
for belt drive applications.
your supplier).
of starts per hour, the load curve/inertia and environmental considerations.
Motor modifications
Operating outside the contractual parameters may
Warning
thermally overload the motor, eg too many starts per
All modifications should be carried out by a trained
hour, or mechanically stress components, eg over-
operative. Do not work under suspended load and
Bearings, grease, bearing change
speeding.
use correct lifting equipment.
Grease
Regreasable bearings are pre-packed with a lithium
Refer to starter literature for methods of start
Changing terminal box position
or lithium complex based grease.
and safety precautions to be taken.
(on multi-mount motors)
Note:
If drain holes were present they may now be
1) Lift motor, using eyebolt or lifting lugs
Running
After one hour of running, check the general vibration levels. If these are excessive, check alignment
(and belt tensioning if belt driven).
provided
2) Slacken / remove the foot fixing bolts
on one foot
3) Pull the foot away from the frame
4) Repeat stages 2 to 3 on the other foot
Some initial bearing noise may be present during the
running-in period. This is normal because the grease
5) Lower the motor onto two pieces of
timber
has to settle down within the bearing. This noise
should disappear after a few hours of operation.
6) Remove the eyebolt or lifting lugs
7) Rotate the motor until the terminal box is
Check that the motor runs up smoothly and within
8) Refit the eyebolt or lifting lugs on the
in the correct position.
the permitted run-up time. Note that repeated start-
machined pads at the top of the motor
ing in quick succession may lead to a thermal over-
(diagonally opposite corners for lifting
load of the motor.
lugs). Ensure that lifting lugs are in
positioned at the top of the motor.
Other lithium based greases of a similar consistency
would be compatible. See table below for some
alternatives:
Alternative lithium complex greases
Grease
Reference
Manufacturer
Energrease
Castrol
Luplex
Unirex
Sovereign
Mobilgrease
Liplex
Hytex
Retinax
LGHT3
LC2
LMX
M2
N2
LS
HP
EP2
EP2
LX
BP
Castrol
Century
Esso
Gulf
Mobil
Shell
Texaco
Shell
SKF
contact with all machined faces and that
Where a special grease has been supplied, this will
Fitting couplings and alignment
the correct bolts and nuts are used.
be indicated on the motor nameplate.
Extreme care must be exercised in lining up cou-
Tighten the bolts to the correct torque.
plings as misalignment can be detrimental to the
9) Remove fan cover
Regreasing
shaft and bearings. For direct drives, we recommend
10) Remove the endshield bolts at both ends
Standard regreasing facilities, where provided, are
that flexible couplings are used. Please ensure that
the alignment instructions given by the coupling
of the motor.
11) Slacken drive end bearing cap or
situated on the periphery of the drive end and nondrive endshields.
manufacturer are followed.
clamping screws to allow endshield
spigot to disengage.
Do not at any time force in the fitting of couplings,
12) If grease nipples are fitted, disengage
Grease relief is via a:
a) Diaphragm relief valve.
pulleys etc. All motors are provided with a threaded
both endshield spigots and rotate the
b) Rotating grease relief flinger.
hole in the drive end shaft to assist fitting and
endshields through 90° until the grease
c) Plugged grease chute.
removal. A bolt should be used in this hole and a nut
nipples are at the top, or the desired
with a large washer used to press the coupling or
pulley against the shoulder of the shaft. Care must
also be taken to ensure that the motor bearings are
not subjected to end-thrust caused by the two halves
of the couplings being squeezed too tightly together.
Please ensure that all couplings, belts, pulleys etc
are properly and permanently guarded against accidental contact while the motor is running.
position.
13) Refit endshield bolts and tighten to the
correct torque.
14) Retighten the bearing cap screws at the
For motors with open bearings and without grease
relief facilities, the old grease must be cleaned out
from time to time by removing the bearing cap
and/or endshield. The bearing and housing must
drive end, replacing the washers
under the bolt heads. Tighten screws to
then be re-packed with grease and reassembled. Do
not overfill the bearing housing - it should not be
the correct torque.
more than a quarter full of grease after reassembly.
15) Lift motor using the eyebolt hooks or the
lifting lugs.
16) Strip paint from the pads where the feet
Motors with sealed for life bearings usually employ a
polyurea EA6 grease. These should be fitted with
Care should be taken to ensure fixing bolts are cor-
are to be fitted and apply a thin film of
new bearings based on the bearing life stated in the
rectly tightened.
grease for corrosion protection on bare
product catalogue.
surfaces.
Belts drives
Please ensure that the V-belts are of the same manufacture and have the same dimensions. Also
ensure that the belts are correctly tensioned in
accordance with the manufacturer’s recommenda-
17) Refit the feet in the reverse order of
dismantling (steps 2 and 3).
18) Ensure the feet are fully in contact with
the machined faces. Tighten all bolts to
the correct torque.
tions. If the V-belts are not tensioned correctly, it can
19) Repeat stages 18 to 19 on the other foot.
cause belt and pulley wear and/or shaft and bearing
20) Prime and paint all machined surfaces
damage. When replacing belts, it is recommended
that all belts be replaced at the same time. It is also
3
left exposed by the changes.
21) Refit fan cover with the greasing hole in
An overgreased bearing will cause overheating of
the bearing with the possible escape of the grease,
loss of lubrication qualities, leading to ultimate bearing failure.
Installation & Maintenance
cover caps. Apply a film of non-setting
Standard regreasing facilities
jointing compound on bare machined
Type
Metric
NEMA
Regreasing
facility
63-180*
56-286
on request
200-355
324-587
standard
* Bearings are double shielded and pre-packed
with grease for life
Lubrication procedure
The following procedure should be adopted:
1) Wipe clean the grease gun fitting and the
Some motors will have one way grease
• No excessive vibration
protection.
• No loose fasteners
4) Fit flange ring onto spigot positioning fixing holes,
where applicable, to provide either BS or DIN
flange hole positions.
5) Bolt ring into position, using the same
size socket head bolts as used on the feet.
These are supplied with the flange ring kit.
6) Tighten the bolts to correct torque.
• Cables and earth are sound
• Sealing of the motor and gland plate in
good condition
• Insulation resistance adequate, imperative
this
is checked after a prolonged shut-down
• Regrease required, particularly large
output 2 pole motors
• Bearing condition
Change from ball/ball to roller/ball construction
200 - 355 ~ 324T - 586 frame
Note:
Smoke extraction motors or motors on safety
valves which should be left in place.
3) Add a small quantity of grease,
lugs/eyebolts
surfaces for sealing and corrosion
regions around the motor grease fittings.
2) Remove the grease relief plug if fitted.
• No significant corrosion of the lifting
1) Isolate motor before commencing work.
critical applications should be rewound, to the
approximately 4 to 10 shots depending
2) Remove fan cover and fan.
original specification, after 40,000 hours of oper-
on frame size.
3) Remove bearing cap screws.
ation. If variable speed employing unipolar
4) Remove endshield at both ends.
switching the period is reduced to 30,000 hours
minutes in order that excess grease may
5) Remove bearing circlips at both ends.
and reduced again to 20,000 hours for bipolar
be expelled before refitting the relief plug.
Bearings fitted with rotating grease relief
6) Remove preload washer at non-drive end.
7) Replace drive end ball bearing with new
switching. In all cases refer to your supplier.
4) Allow motor to run for approximately 10
or through grease valves will relieve
automatically. Grease may not be
expelled from the motor during filling due to
internal cavities/pipes filling or relief via seals.
5) On initial start up or after relubrication,
‘bearing noise’ may result from the new
grease moving around the bearing. This
noise is normal and will disappear after a
few hours of running.
Bearing change
When fitting new bearings, the parts should be
lightly lubricated with grease.
roller bearing and refit circlip.
8) Remove non-drive end ball bearing and
inner bearing cap.
9) Fit new non-drive end inner bearing cap
endshield bolts/studs. The endshields should then
be eased off their spigots.
10) Examine existing non-drive end ball
bearing and either refit or replace.
stator, taking care not to damage the stator bore
12) Re-pack bearings with new grease in
and both stator and rotor windings.
accordance with recommendations.
13) Ensure the lip on both oilseals is
Having dismantled the motor, maintenance can be
greased.
a)
b)
c)
tion heating. The temperature must be controlled to
120°C maximum. Suitable handling precautions
carried out to remove all dirt. For this purpose, the
use of an air line supplying dry compressed air
spacer O/D is the same
under comparatively low pressure is best, as a high
as the bearing O/D
velocity airstream can force dirt into the spaces
bearing spacer supplied is fitted into
between the windings and insulation etc. Grease-
the non-drive end and endshield
removing solvents should only be used very sparing-
bearing recess
ly to avoid damage to impregnating varnish or insu-
slots in inner bearing caps are
lation.
aligned with endshield grease chutes
d)
correct location for bearing cap by
Motors should be re-assembled in the reverse order
e)
the use of a stud
bolts are torqued up to
from dismantling, remembering to ease endshields
onto bearings and spigots. Do not use force. On re-
recommended figures
assembly oilseals to mating faces should be lubricat-
should be taken.
The bearing should then be quickly slipped into
ed. If oilseals are worn or damaged during disman-
place, ensuring that the bearing is in contact with the
shaft shoulder.
The rotor can now be carefully withdrawn from the
11) Refit non-drive end bearing circlip.
On larger motors, it is easier to raise the temperature of the bearing using an oil bath, oven or induc-
clamped, pinned or knurl located to the shaft extension. Loosen and remove bearing cover screws and
drive end inner bearing cap.
sure on the inner race only using a short length of
tube placed over the motor shaft.
Remove the fan cover and the fan which is keyed,
with shallow recess (identical to existing
14) Refit both endshields and check that:
The bearing should be driven onto the shaft by pres-
Periodic maintenance
Maintenance
tling then they should be replaced before continuing.
Ongoing maintenance
When cool, ensure that the bearing is clean and
Induction motors by their very nature require very lit-
Before starting the motor, check that the rotor
charge the bearing with the recommended quantity
tle maintenance. However a regular regime of
revolves freely. Ensure that the electrical connec-
of grease. Bearings and housings should be approx-
inspection is recommended to ensure minor prob-
tions are correct and terminal nuts tight (see section
imately a quarter full.
lems do not escalate to breakdowns. Typical inter-
- Electrical Connection).
vals would be 2000 hours of operation or 3 months,
Fitting flange adaptor (where applicable)
whichever is the sooner.
Spares and repairs
1) If required, remove foot as detailed in
terminal box position change.
Checklist:
When ordering spares, it is important to state the
motor serial number to ensure that the correct
2) If required, reposition terminal box and
• No visible damage, ie fans cracked, fan
spares will be supplied.
lifting lugs.
3) Clean paint off the drive end endshield
spigot and remove all the plastic bolt-hole
4
cowls bent, foot cracked etc
• No accumulation of dust or fibres on the
frame or around the fan inlet
Installation & M a i n t e n a n c e
Notes
Fixing bolts, nuts, studs, screws, spacers or washers
Contact must be made prior to any remedial action
are not included with these parts and, if required,
being taken under warrantee
should be clearly specified on the order in addition to
the part description number. The fixing duty and part
Please quote the motor serial number in all such
description reference number for which they are
cases with full details of the problem.
required, should also be clearly stated.
Exploded view of a typical standard ac motor
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
5
Part description
Flange endshield
Endshield fixing bolt
Drive end endshield
Rotor assembly
Flinger (when fitted)
Drive end oil seal (when fitted)
Preload washer
Drive end bearing
Stator assembly with or without feet
Eyebolt (when fitted) or dual lifting lug
Bearing retention circlip
Non-drive end bearing
Non-drive end endshield
Endshield fixing bolt
Bearing circlip
Ref
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Part description
Non-drive end oilseal (when fitted)
Fan
Fan circlip
Fan cover
Fan cover screw and washer
Foot fixing bolts and washer (where applicable)
Feet
Terminal board (when fitted)
Terminal box to frame gasket
Terminal box
Internal earth terminal
Terminal box lid gasket
Terminal box lid
Pad mounting bracket
Face endshield
Bearing Information
Bearing references and oil seals for horizontally-mounted motors only
IEC Type
Bearings(1)
Oil seals(2)
European
BS
Polarity
Drive end
Non-drive end
Drive end
63
63
All
62022Z
62022Z
71
80M
71
80M
All
All
60032Z
62042Z
60032Z
60032Z
15 x 24 x 5(3)
17 x 28 x 6(3)
20 x 30 x 7(3)
15 x 24 x 5(3)
17 x 28 x 6(3)
15 x 24 x 5(3)
90S/L
90S/L
All
62052Z
62032Z
100L
100L
All
62062Z
62052Z
25 x 35 x 7(3)
30 x 42 x 7(3)
17 x 28 x 6(3)
25 x 37 x 7(3)
112M
112M
All
62062Z
62052Z
132S/M
132S/M
All
62082Z
63052Z
30 x 42 x 7(3)
40 x 52 x 7(3)
25 x 37 x 7(3)
25 x 37 x 7(3)
160M/L
180M/L
160M/L
180M/L
All
All
63092Z
63102Z
63072Z
63082Z
45 x 60 x 8(3)
50 x 65 x 8(3)
35 x 47 x 7(3)
40 x 52 x 7(3)
200LX
200LX
All
6312
6312
225S
225S
All
6313
6313
225M
225M
All
6314
6314
250ME
250S
2
6314
6314
60 x 80 x 8(3)
65 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
60 x 80 x 8(3)
65 x 90 x 10 (4)
70 x 90 x 10 (4)
70 x 90 x 10 (4)
280SE
250M
315SE
280M
315ME
315S
90 x 120 x 12 (3)
70 x 90 x 10(4)
90 x 120 x 12 (3)
70 x 90 x 10(4)
90 x 120 x 12 (3)
70 x 90 x 10(4)
90 x 120 x 12 (3)
70 x 90 x 10 (4)
90 x 120 x 12 (3)
70 x 90 x 10 (4)
90 x 120 x 12 (3)
70 x 90 x 10 (4)
315M
315M
315L
315L
355S/M/L
355S/M/L
6316
6314
6318
6314
6318
6316
6319
6316
6319
6316
6319
6316
6319
6316
6324
80 x 110 x 10(3)
70 x 90 x 10 (4)
280S
6316
6314
6318
6314
6318
6316
6319
6316
6319
6316
6319
6316
6319
N316
N324
80 x 110 x 10(3)
70 x 90 x 10(4)
280ME
4 up
2
4 up
2
4 up
2
4 up
2
4 up
2
4 up
2
4 up
2
4 up
90 x 120 x 12 (3)
70 x 90 x 10(4)
90 x 120 x 12 (3)
70 x 90 x 10(4)
90 x 120 x 12 (3)
75 x 100 x 10 (4)
90 x 120 x 12 (3)
70 x 90 x 10 (4)
90 x 120 x 12 (3)
70 x 90 x 10 (4)
90 x 120 x 12 (3)
75 x 100 x 10 (4)
Non-drive end
115 x 145 x 14(3) 115 x 145 x 14(3)
(1) Frame sizes 80 and 90 have bearings with CN clearances, frame sizes 100 to 355 have bearings with C3 clearance ‘medium’ series
(2) Sizes given are in mm, and represent bore x outside diameter x width
Material: (3) Nitrile rubber (4) Silicon rubber
Bearing references and oil seals for horizontally-mounted motors only
NEMA Type
Frame
56
143/5T
182/4T
213/5T
254/6T
284/6T
324T
326T
364T
365T
404/5T
444/7T
504/5
(1)
(2)
6
Bearings(1)
Oil seals (2)
Polarity
Drive end
Non-drive end
All
All
All
All
All
All
All
All
All
2
4 up
2
4 up
2
4 up
2
4 up
62042Z
62052Z
62062Z
62082Z
63092Z
63102Z
6312
6313
6314
6314
6316
6314
6318
6316
6319
6316
6319
60032Z
62032Z
62052Z
63052Z
63072Z
63082Z
6312
6313
6314
6314
6316
6314
6318
6316
6319
6316
6319
Drive end
15 x 24 x 5(3)
17 x 28 x 6(3)
30 x 42 x 7(3)
40 x 52 x 7(3)
45 x 60 x 8(3)
50 x 65 x 8(3)
60 x 80 x 8(3)
65 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
90 x 120 x 12 (3)
70 x 90 x 10(4)
90 x 120 x 12 (3)
90 x 120 x 12 (3)
90 x 120 x 12 (3)
Non-drive end
15 x 24 x 5(3)
17 x 28 x 6(3)
25 x 37 x 7(3)
25 x 37 x 7(3)
35 x 47 x 7(3)
40 x 52 x 7(3)
60 x 80 x 8(3)
65 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
90 x 120 x 12(3)
70 x 90 x 10(4)
90 x 120 x 12(3)
90 x 120 x 12(3)
90 x 120 x 12(3)
Frame sizes 56 to143/5T have bearings with CN clearances, frame sizes 182T to 505 have bearings with C3
clearance ‘medium’ series
Sizes given are in mm, and represent bore x outside diameter x width
Material: (3) Nitrile rubber (4) Silicon rubber
Connection Diagrams - IEC Frames
7
Connection Diagrams - NEMA
8
Fault Finding - Three Phase Induction Motors
Motor will not start
Supply or starter trips out at
start
1. Fault with supply.
1. Check for correct voltage at
motor terminals.
2. Motor or load locked up.
2. Make sure motor and load
are free to turn.
3. Wrong connection in control 3. Check to ensure contactors
circuit.
operate.
1.. Fit new fuses, reset circuit
breakers, etc.
2. Remove clamps, locks etc.
1. Wrong or loose
connections.
1. Fix up connections.
1. Check all lugs are properly
crimped or soldered, and
connections are tight.
2. Motor overloaded.
2. Check load performance
data against motor
performance data.
3. Inertia of load too high.
3. Measure voltage at motor
terminals while motor starting.
4. Low voltage due to volt drop 4. Check settings of overload
in cables.
and circuit breaker and allow
for starting current.
5. Overload or circuit breaker
incorrectly set or sized.
Motor starts but has no torque. 1. Incorrect connection.
Motor does not reach full speed
or takes a long time to
2. Delta wound motor
accelerate
connected in star.
1. Check connection diagram
and nameplate data.
2. Check load performance
data against motor
performance data.
3. Star/Delta starter staying in 3. Measure voltage at motor
star.
terminals while motor starting.
3. Sort out control circuit.
2. Change motor for correct
size.
3. Change cables for correct
size.
4. Correct setting of overload
or breaker or change.
1. Sort out and correct
connections.
2. Check timer and starter
control circuit.
3. Change motor for correct
size.
4. Inertia of load too high.
5. Motor overloaded.
4. Change cables for correct
size.
6. Low voltage due to drop in
cables.
Motor overheating
1. Motor overloaded.
2. Ineffective cooling.
Temperature of air.
Look for build up of dirt
3. Excessiive ambient.
4. Wrong connections.
5. Delta wound motor in star.
6. Motor ‘Single Phasing”.
1. Check load performance
data.
2. Check fan and air flow.
1. Fix problem with load or fit a
larger motor.
2. Clean motor. Sort out cool
ing of air temp. and flow.
3. Check connection diagram
and nameplate data.
4. Check volts and amps on all
three phases.
5. Check nameplate
3. Sort out connections.
6. Check phase to phase
voltage accurately.
6. Balance supply or accept
unbalance
1&2. Check connection
diagram
1&2. Sort out and correct
connections at motor terminals.
3. Measure voltage at motor
terminals.
3. Connect supply voltage.
4. Restore supply to all phases
5. Correct voltage or frequency
7. Wrong voltage or frequency.
8. Supply voltage unbalanced.
No load amps in excess of full
load amps.
1. Incorrect connection.
2. Star wound motor
connected Delta.
3. Voltage in excess of
nameplate.
4. Motor supplied for a
4. Compare supply voltage and
different voltage or frequency. frequency to nameplate.
9
4. Change motor for correct
voltage and frequency.
Fault Finding - Three Phase Induction Motors
Mechanical noise or vibration.
Noisy bearings. Bearings
overheating
1. Thrust from load or
misalignment..
1. Check gaps between cou
pling halves and alignment.
1. Re-align couplings.
2. Damaged bearings, too
much grease, no grease, or
foreign matter in grease.
2&3. Turn shaft slowly by hand 2&3. Clean bearing housing,
change bearings and repack
and feel for roughness or
stiffness. Check for bent shaft with fresh grease.
or fan rubbing.
3. Rotor pulling or foreign
matter in air gap.
4. Out of balance load,
coupling or pulley.
5. Excessive belt pull.
Motor amps in excess of
nameplate full load amps on
load.
4. Run motor disconnected
from load and then with pulley
or coupling removed.
5. Run motor without belts.
4. Fix up out of balance items.
5. Loosen belt tension.
6. Motor foundations not ridgid 6. Check design and
construction foundations.
performance data.
6. Increase strength of
foundations.
1. Motor overloaded
1. Check load and
performance data.
2. Measure voltage at motor
terminals.
3. Check nameplate data.
1. Fix problem with load or fit
larger motor.
2. Fix problem, maybe with
larger cables.
3. Correct voltage or frequency
4. Wrong connections.
4. Check nameplate data..
4. Sort out and correct.
5. Motor “Single Phasing”.
5&6 Check volts and amps in
all three phases.
5&6 Resore balanced supply
to all three phases.
2. Low voltage supply
3. Wrong voltage and
frequency.
6. Supply voltage unbalanced
Excessive electrical noise
7. Motor speed not matched to 7. Measure motor speed and
load.
check load requirements.
1. Wrong connections
1. Check connections.
7. Change motor for correct
motor speed.
1. Fix connections.
2. Wrong voltage.
2. Check voltage with
nameplate.
3. Check volts and amps on all
three phases.
1. Measure phase to phase
voltage accurately.
2. Correct voltage.
1. Watch shaft rotation.
1. Swap any two phases of
supply.
3. Motor “Single Phasing”
Unbalanced amps in different
phases when motor loaded
1. Unbalanced power supply.
Motor runs in wrong direction
1. Wrong connections.
10
3. Restore supply to all phases
1. Balance supply or accept
unbalance
Customer Service
CALL TOLL FREE - NORTH AMERICA:
1-800-463-8917
OR
1-800-668-6779
FAX:
416-675-6885
847-253-9880
Quebec only:
1-888-668-9843
Fax:514-636-4253
www.brookcromptonna.com
Every care has been taken to ensure the accuracy
of the information contained in this publication, but,
due to a policy of continuous development and
improvement the right is reserved to supply
products which may differ slightly from those
illustrated and described in this publication
Brook Crompton
264 Attwell Drive
Toronto, Ontario M9W 5B2
Tel: 416 675-3844
Fax: 416 675-6885
Internet: www.brookcromptonna.com
Printed in Canada
15/09/04 - 2004.W.OI Issue 1
© Copyright 2002. Brook Crompton. All rights reserved
Z - Variable Frequency Drives
Issue Date : 2011-09-30
Variable Frequency Drives
As variable frequency drives (VFDs) from multiple manufacturers are used in Seresco Technologies Inc.'s
products, please ensure that you are aware which model is used in your unit before consulting this guide.
Siemens MicroMaster VFDs
WARNING This equipment contains dangerous voltages and controls potentially dangerous
rotating mechanical parts. Non-compliance with Warnings failure to follow the instructions contained in
this manual can result in loss of life, severe personal injury or serious damage to property. Only suitable
qualified personnel should work on this equipment, and only after becoming familiar with all safety
notices, installation, operation and maintenance procedures contained in this manual. The successful and
safe operation of this equipment is dependent upon its proper handling, installation, operation and
maintenance.
WARNING The DC link of all MICROMASTER modules remains at a hazardous voltage level
for 5 minutes after all voltages have been disconnected. Therefore always wait for 5 minutes after
disconnecting the inverter from the power supply before carrying out work on any modules. The drive unit
discharges itself during this time.
This equipment is capable of providing internal motor overload protection in accordance with UL508C section
42. Refer to P0610 (level 3) and P0335. Motor overload protection can also be provided using an external PTC
via a digital input. This equipment is suitable for use in a circuit capable of delivering not more than 10,000
symmetrical amperes (rms), for a maximum voltage of 230/460 V when protected by an H or K type fuse, a
circuit breaker or self-protected combination motor controller controller (for more details see Operating
Instructions Appendix F). Use Class 1 60/75 °C copper wire only with the cross-sections as specified in the
Operating Instructions.
Before installing and commissioning, please read these safety instructions and warnings carefully and all the
warning labels attached to the equipment. Make sure that the warning labels are kept in a legible condition and
replace missing or damaged labels.
Table 1. Maximum permissible ambient temperature
Frame Sizes A-F
50 °C at constant torque (CT) and 100 %
40 °C at variable torque (VT) and 100 %
1
Z - Variable Frequency Drives
Frame Sizes FX and GX
Issue Date : 2011-09-20
40 °C at 100 % permissible output current
MM420
MM440
Figure 1. MM420 Block Diagram
Figure 2. MM440 Block Diagram
Figure 3. MM420 LED Status Display
Figure 4. MM440 LED Status Display
2
Z - Variable Frequency Drives
Issue Date : 2011-09-30
Table 2. Fault Messages
MM420
Fault
Significance
MM440
Fault
Significance
F0001
Overcurrent
F0002
Overvoltage
F0002
Overvoltage
F0003
Undervoltage
F0003
Undervoltage
F0004
Inverter Overtemperature
F0004
Inverter Overtemperature
F0005
Inverter I2t
F0005
Inverter I2t
F0011
Motor Overtemperature I2t
F0011
Motor Overtemperature I2t
F0012
Inverter temp. Signal lost
F0015
Motor temp. Signal lost
F0010
Mains Phase Missing
F0021
Earth Fault
F0022
HW Monitoring Active
F0023
Output Fault
F0024
Rectifier Overtemperature
F0030
Fan Has Failed
F0035
Auto Restart after n
F0040
Automatic Calibration Failure
F0041
Motor Data Identification Failure
F0042
Speed Control Optimization Failure
F0041
Stator resistance measurement failure
F0051
Parameter EEPROM Fault
F0051
Parameter EEPROM Fault
F0052
Powerstack Fault
F0052
Powerstack Fault
F0053
IO EEPROM Fault
F0054
Wrong IO Board
F0060
Asic Timeout
F0060
Asic Timeout
F0070
Communications board setpoint error
F0070
Communications board setpoint error
F0071
No Data for USS (RS232 link) during Telegram Off Time
F0071
USS (BOP Link) setpoint fault
F0072
No Data from USS (RS485 link) during Telegram Off Time
F0072
USS (COM Link) setpoint fault
F0080
Analogue input - lost input signal
F0080
Analogue input - lost input signal
F0085
External Fault
F0085
External Fault
F0090
Encoder Feedback Loss
F0101
Stack Overflow
F0101
Stack Overflow
F0221
PI Feedback below minimum value
F0221
PI Feedback below minimum value
F0222
PI Feedback above maximum value
F0222
PI Feedback above maximum value
F0450
BIST Tests Failure
F0450
BIST Tests Failure
F0452
Belt Failure Detected
3
Z - Variable Frequency Drives
Issue Date : 2011-09-20
Table 3. Alarm Messages
MM420
Alarms
4
MM440
Significance
Alarms
Significance
A0501
Current Limit
A0501
Current Limit
A0502
Overvoltage limit
A0502
Overvoltage limit
A0503
Undervoltage Limit
A0503
Undervoltage Limit
A0504
Inverter Overtemperature
A0504
Inverter Overtemperature
A0505
Inverter I2t
A0505
Inverter I2t
A0506
Inverter Duty Cycle
A0506
Inverter Duty Cycle
A0511
Motor Overtemperature I2t
A0511
Motor Overtemperature I2t
Z - Variable Frequency Drives
Issue Date : 2011-09-30
A0541
A0600
A0700 - AO709
Motor Data Identification Active
RTOS Overrun Warning
CB warning
A0520
Rectifier Overtemperature
A0521
Ambient Overtemperature
A0522
I2C read out timeout
A0523
Output fault
A0535
Braking Resistor Output
A0541
Motor Data Identification Active
A0542
Speed Control Optimization Active
A0590
Encoder feedback loss warning
A0600
RTOS Overrun Warning
A0700 - AO709
CB warning
A0710
CB communication error
A0710
CB communication error
A0711
CB configuration error
A0711
CB configuration error
A0910
Vdc-max controller de-activated
A0910
Vdc-max controller de-activated
A0911
Vdc-max controller active
A0911
Vdc-max controller active
A0912
Vdc-min controller active
A0920
ADC parameters not set properly
A0920
ADC parameters not set properly
A0921
DAC parameters not set properly
A0921
DAC parameters not set properly
A0922
No load applied to inverter
A0922
No load applied to inverter
A0923
Both JOG Left and JOG Right are
A0923
Both JOG Left and JOG Right are
requested
requested
A0952
Belt Failure Detected
A0936
PID Autotuning Active
5
Z - Variable Frequency Drives
Issue Date : 2011-09-20
ABB VFDs
ACS 350
WARNING Ignoring the following instructions can cause physical injury or death, or damage to
the equipment. Only qualified electricians are allowed to install and maintain the drive! Never work on the
drive, motor cable or motor when input power is applied. After disconnecting the input power, always wait
for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive,
motor or motor cable.
Before performing any maintenance activity, ensure by measuring with a multimeter (impedance at least 1
Mohm) that:
1. There is no voltage between the drive input phases U1, V1 and W1 and the ground.
2. There is no voltage between terminals BRK+ and BRK- and the ground.
Do not work on the control cables when power is applied to the drive or to the external control circuits.
Externally supplied control circuits may carry dangerous voltage even when the input power of the drive is
switched off.
Do not make any insulation or voltage withstand tests on the drive.
If a drive whose EMC filter is not disconnected is installed on an IT system [an ungrounded power system
or a high resistance-grounded (over 30 ohms) power system], the system will be connected to earth potential
through the EMC filter capacitors of the drive. This may cause danger or damage the drive.
If a drive whose EMC filter is not disconnected is installed on a corner grounded TN system, the drive will
be damaged.
WARNING Even when the motor is stopped, dangerous voltage is present at the power circuit
terminals U1, V1, W1 and U2, V2, W2 and BRK+ and BRK-
WARNING The drive is not field repairable. Never attempt to repair a malfunctioning drive;
contact your local ABB representative or Authorized Service Center for replacement. Make sure that dust
from drilling does not enter the drive during the installation. Electrically conductive dust inside the drive
may cause damage or lead to malfunction. Ensure sufficient cooling.
6
Z - Variable Frequency Drives
Issue Date : 2011-09-30
Operation and Start-up
Do not activate automatic fault reset functions if dangerous situations can occur. When activated, these
functions will reset the drive and resume operation after a fault.
Do not control the motor with an AC contactor or disconnecting device (disconnecting means); use instead
the control panel start and stop keys or external commands (I/O or fieldbus). The maximum allowed
number of charging cycles of the DC capacitors (i.e. power-ups by applying power) is two per minute and
the maximum total number of chargings is 15 000.
If an external source for start command is selected and it is ON, the drive will start immediately after an
input voltage break or fault reset unless the drive is configured for 3 wire (a pulse) start/stop.
When the control location is not set to local (LOC not shown on the display), the stop key on the control
panel will not stop the drive. To stop the drive using the control panel, press the LOC/REM key LOC and
then the stop key.
Figure 5. ACS 350 Block Diagram
7
Z - Variable Frequency Drives
Table 4. Alarm and Fault Codes
8
Issue Date : 2011-09-20
Issue Date : 2011-09-30
Z - Variable Frequency Drives
9
Z - Variable Frequency Drives
10
Issue Date : 2011-09-20
Issue Date : 2011-09-30
Z - Variable Frequency Drives
11
Z - Variable Frequency Drives
12
Issue Date : 2011-09-20
Issue Date : 2011-09-30
Z - Variable Frequency Drives
13
Z - Variable Frequency Drives
14
Issue Date : 2011-09-20
Issue Date : 2011-09-30
Z - Variable Frequency Drives
15
Z - Variable Frequency Drives
16
Issue Date : 2011-09-20
Issue Date : 2011-09-30
Z - Variable Frequency Drives
ACH 550
WARNING The ACH550 adjustable speed AC drive should ONLY be installed by a qualified
electrician.
WARNING Even when the motor is stopped, dangerous voltage is present at the power circuit
terminals U1, V1, W1 (L1, L2, L3) and U2, V2, W2 (T1, T2 T3) and, depending on the frame size, UDC+
and UDC-, or BRK+ and BRK-
WARNING Dangerous voltage is present when input power is connected. After disconnecting the
supply, wait at least 5 minutes (to let the intermediate circuit capacitors discharge) before removing the
cover. Even when power is switched off from the input terminals of the ACH550, there may be dangerous
voltage (from external sources) on the terminals of the relay outputs.
WARNING When the control terminals of two or more drives are connected in parallel, the
auxiliary voltage for these control connections must be taken from a single source which can either be one
of the drives or an external supply. 1-4 ACH550-UH User’s Manual Safety
WARNING Disconnect the internal EMC filter when installing the drive on an IT system (an
ungrounded power system or a high-resistance-grounded [over 30 ohm] power system).
WARNING Do not attempt to install or remove EM1, EM3, F1 or F2 screws while
power is applied to the drive’s input terminals.
WARNING Do not control the motor with the disconnecting device (disconnecting means);
instead, use the control panel keys or commands via the I/O board of the drive. The maximum allowed
number of charging cycles of the DC capacitors (i.e. power-ups by applying power) is five in ten minutes.
WARNING Never attempt to repair a malfunctioning ACH550; contact the factory or your local
Authorized Service Center for repair or replacement.
17
Z - Variable Frequency Drives
Issue Date : 2011-09-20
WARNING The ACH550 will start up automatically after an input voltage interruption if the
external run command is on.
Figure 6. Wiring Diagram ACH 550
18
Issue Date : 2011-09-30
Z - Variable Frequency Drives
Figure 7. Wiring Diagram ACH 550
19
english
ECblue
Basic Version
EC-fans with highest efciency
Assembly instructions
Software version: D1583...87A, D1680A from Version 1.00
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
Assembly instructions ECblue
Content
1
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Structure of the assembly instructions . . . . . . . . . . . . . . . . . . . .
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
4
4
4
2
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Use as intended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Explanations of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Requirements placed on the personnel / due diligence . . . . . . .
2.6 in the Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 Working on device / Hazards through “residual voltage” . . . . . .
2.8 Modications / interventions in the device . . . . . . . . . . . . . . . . .
2.9 Operator’s obligation of diligence . . . . . . . . . . . . . . . . . . . . . . . .
2.10 Employment of external personnel . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
6
6
6
7
7
8
8
9
3
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Application operational area . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Ziehl-Abegg design criteria for long service life . . . . . . . . . . . . .
3.4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Waste disposal / recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
9
10
10
11
11
4
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Connection lead & terminal box . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Installation of axial fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
12
13
4.3.1
4.3.2
4.4
4.5
Fan designs A, D, K, S and W (without nozzles) . . . . . . . .
Installation in an exhaust air stack, design T . . . . . . . . . . .
13
14
Installation of centrifugal fans . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
4.4.1
4.4.2
Assembly of centrifugal fans, RH design . . . . . . . . . . . . . .
Erecting the equipment: Design ER...-..N... / ER...-..K... / GR...
16
4.4.3
Optimal installation distances according to for RH.. / ER fans
Outdoor fans in a humid atmosphere . . . . . . . . . . . . . . . . . . . . .
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17
17
17
Assembly instructions ECblue
4.6
5
Motorheating
.......................................
18
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
18
18
5.2.1
5.2.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
Motor size “B” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor size “D” and “G” . . . . . . . . . . . . . . . . . . . . . . . . . .
19
20
EMC-compatible installation of control lines . . . . . . . . . . . . . . . .
Mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
5.4.1
5.4.2
5.4.3
21
21
22
Line voltage for 1~ types . . . . . . . . . . . . . . . . . . . . . . . . .
Line voltage for 3~ types . . . . . . . . . . . . . . . . . . . . . . . . .
Required quality attributes for the mains voltage . . . . . . . . .
Residual-current-operated protective device . . . . . . . . . . . . . . . .
Motor protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog input (0...10 V) for setting fan speed . . . . . . . . . . . . . . .
Output voltage +10 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage supply for external devices, only motor sizes “D”, “G”
(+24 V, GND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enable, device ON / OFF (Digital In 1 = D1) . . . . . . . . . . . . . . .
Relay outputs (K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tacho out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Status Out OC (motor size “B”) . . . . . . . . . . . . . . . . . . . .
Potential at control voltage connections . . . . . . . . . . . . . . . . . . .
Add-on modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24
25
25
25
25
25
6
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Prerequisites for commissioning . . . . . . . . . . . . . . . . . . . . . . . . .
26
26
7
Diagnostics / Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 For motor size “D” and “G” Status LED with ash code . . . . . . .
27
27
29
8
Service work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Repairs / maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
32
9
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 EC Declaration of Incorporation . . . . . . . . . . . . . . . . . . . . . . . . .
32
32
34
36
5.10
5.11
5.12
5.13
5.14
5.15
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22
23
23
24
Assembly instructions ECblue
9.4
9.5
9.6
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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38
39
39
Assembly instructions ECblue
1
1.1
1.2
1.3
1.4
General notes
General notes
Structure of the assembly instructions
Before installation and start-up, read this assembly instructions carefully to ensure correct use!
We emphasize that these assembly instructions apply to specic units only, and
are in no way valid for the complete system!
Use these assembly instructions to work safely with and on the device. They contain
safety instructions that must be complied with as well as information that is required for
failure-free operation of the device.
Keep these assembly instructions together with the device. It must be ensured that all
persons that are to work on the device can refer to the assembly instructions at any time.
Keep the assembly instructions for continued use. They must be passed-on to all
successive owners, users and nal customers.
Target group
The assembly instructions address persons entrusted with planning, installation, commissioning and maintenance and servicing and who have the corresponding qualications and skills for their job.
Exclusion of liability
Concurrence between the contents of these assembly instructions and the described
hardware and software in the device has been examined. It is still possible that noncompliances exist; no guarantee is assumed for complete conformity. To allow for future
developments, construction methods and technical data given are subject to alteration.
We do not accept any liability for possible errors or omissions in the information contained in data, illustrations or drawings provided.
Ziehl-Abegg AG is not liable for damage due to misuse, incorrect use, improper use or
as a consequence of unauthorized repairs or modications.
Copyright
These assembly instructions contain copyright protected information. The assembly
instructions may be neither completely nor partially photocopied, reproduced, translated
or put on data medium without previous explicit consent from Ziehl-Abegg AG. Infringements are liable for damages. All rights reserved, including those that arise through
patent issue or registration on a utility model.
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Assembly instructions ECblue
2
2.1
Safety information
Safety information
This chapter contains instructions to prevent personal injury and property damage.
These instructions do not lay claim to completeness. In case of questions and problems,
please consult our company technicians.
Use as intended
Attention!
• The fans are only intended for the conveyance of air or mixtures similar to
air.
• Other uses which do not coincide with, or which exceed those specied will
be deemed unauthorised unless contractually agreed. Damages resulting
from such unauthorised uses will not be the liability of the manufacturer.
The user will assume sole liability.
• They must not be used in hazardous areas for the transfer of gas, mist
vapours or mixtures. Nor must they be used for the transfer of solid components in the transfer medium.
• Reading these document and complying with all contained instructions -especially
the safety notications contained therein -are considered part of intended use.
• To consider is also the documentation of attached components.
2.2
Improper use
Improper use / reasonably foreseeable misuse
• Conveyance of aggressive and explosive gaseous media
• Use in an explosive atmosphere
• Operation with iced up fan wheels
• Conveyance of abrasive or adhesive media
• Conveyance of liquid media
• Use of the fan and add-on parts (e.g. safety grille) as a resting surface or climbing
aid
• Unauthorised constructional modications to the fan
• Operation of the fan as a safety component or for the performance of safetyrelevant functions in the sense of DIN EN ISO 13849-1.
• Blocking or braking of the fan by inserting objects
• Loosening of the impeller from the motor
• All applications not listed in the intended use
Not the manufacturer, rather the operator of the frequency inverter is liable for any
personal harm or material damage arising from non-intended use.
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Assembly instructions ECblue
2.3
Safety information
Explanations of symbols
Safety instructions are highlighted with warning triangles and are depicted according to
the degree of hazard as follows.
Attention!
Hazardous area. Death or severe injury or signicant property damage can occur if
the corresponding precautions are not taken!
Danger owing to electric current
Danger owing to electric current or voltage.
Information
Important information and advice for user.
2.4
2.5
Product safety
The device conforms to the state of the art at the time of delivery and is fundamentally
considered to be reliable. The device and its accessories must only be used in a awless
condition and installed and operated in compliance with the assembly instructions and/or
operating instructions. Operating outside the device's technical specications (F rating
plate and attachment / technical data) can lead to a defect in the device and additional
damage!
A separate fault and performance monitoring-system with an alarm signal function
is necessary in order to prevent personal injuries and material damages during
malfunctions and in case the device fails. Substitute operation must be taken into
consideration! The design and installation of the system must comply with local
regulations and directives.
Requirements placed on the personnel / due diligence
Persons entrusted with the planning, installation, commissioning and maintenance and
servicing in connection with the frequency inverter must have the corresponding qualications and skills for these jobs.
In addition, they must be knowledgeable about the safety regulations, EU directives,
rules for the prevention of accidents and the corresponding national as well as regional
and in-house regulations. Personnel to be trained or instructed and apprentices are only
permitted to work on the device under the supervision of an experienced person. This
also applies to personnel undergoing general training. Comply with the legal minimum
age.
This device is not intended to be used by people (including children) who have restricted
mental, sensory or intellectual abilities or who have a lack of experience and/or knowledge.
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Assembly instructions ECblue
2.6
Safety information
in the Operation
Danger owing to electric current
• Any faults detected in the electric system/modules/operating equipment must be
corrected immediately. If these faults are not corrected, the device/system is
potentially very dangerous. The device/system must therefore not be operated
when it is faulty.
• Fuses must always be replaced only, never repaired or bridged. The specications
for maximum prefusing must always be adhered to (F Technical data). Only fuses
cited in the electrical circuit diagram may be used.
Attention, danger of being sucked in!
• Danger of being sucked in: Do not wear loose or hanging clothing, long hair,
jewellery, etc.
2.7
Working on device / Hazards through “residual voltage”
Information
Installation, electrical connection, and start-up operation may only be carried out
by an electrical specialist in accordance with electrotechnical regulations (e.g. DIN
EN 50110 or DIN EN 60204).
Danger owing to electric current
• It is forbidden to carry out work on electrically live parts. Protection class of
the device when open is IP 00! It is possible to inadventently touch components carrying hazardous voltages!
• The rotor is not protected by insulation nor grounded to earth in accordance
with DIN EN 60204-1, and for this reason the system constructor must
provide protection by casing in accordance with DIN VDE 0100-410, before
the motor is connected to a power source. This protection can be achieved
for example by a protection grating (F Product overview: Application operational area and Installation: General).
• When the motor runs independently due to air owing through or if it
continues to run down after being turned off, dangerous voltages of over
50 V can arise on the motor internal connections through operation of the
generator.
• The safe isolation from the supply must be checked using a two-pole voltage
detector.
• Even after disconnecting the mains voltage, life-threatening charges can appear
between the protective ground “PE” and the mains connection.
• The protective conductor is routed over high discharge currents (irrespective of the
clock frequency, current-source voltage and motor capacity). Earthing in
compliance with VDE specications shall therefore be observed even for testing
and trial conditions (EN 50 178, Art. 5.2.11). Without earthing, dangerous voltages
can be present on the motor housing.
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Assembly instructions ECblue
•
Safety information
Maintenance work may only be carried out by suitably qualied personnel.
Waiting period at least 3 minutes!
Through use of capacitors, danger of death exists even after switching off the
device through directly touching the energized parts or due to parts that have
become energized due to faults.
The controller housing may only be removed or opened when the power line has
been switched off and a period of three minutes has elapsed since switching it off.
Attention, automatic restart!
• The fan may switch on and off automatically for functional reasons.
• After power failure or mains disconnection an automatic restart of the fan takes
place after voltage return.
• Wait for the fan to come to a complete standstill before approaching it.
Attention, hot surface!
• Temperatures of up to approx. 85 °C can arise on the controller housing!
2.8
Modications / interventions in the device
Attention!
For reasons of safety, no unauthorized interventions or modications may be made on
the device. All planned modications must be authorized by the manufacturer in writing.
Use only genuine spare parts / genuine wearing parts / genuine accessories from ZiehlAbegg.These parts were specically designed for the device. There is no guarantee that
parts from non-original sources are designed and manufactured in correspondence with
load and safety requirements.
Parts and optional equipment not supplied by Ziehl-Abegg are not approved by ZiehlAbegg for use.
2.9
Operator’s obligation of diligence
•
•
•
•
•
•
The contractor or owner must also ensure that the electric systems and equipment
are operated and maintained in accordance with electro-technical regulations.
The owner is obliged to ensure that the device are operated in perfect working
order only.
The device may only be used as intended (F “Application”).
You must periodically examine the safety equipment for their properly functioning
condition.
The assembly instructions and/or operating instructions are always readily available at the location where the device is being used, are complete and are in
legible condition.
These persons are regularly instructed in all applicable questions regarding occupational safety and environmental protection and are knowledgeable regarding
the assembly instructions and/or operating instructions and, especially, are familiar with the safety instructions contained therein.
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•
2.10
3
3.1
Product overview
All safety and warning notices attached to the frequency inverter are never
removed and remain legible.
Employment of external personnel
Maintenance and service work are frequently carried out by external employees who
often do not recognize the specic situations and the thus resulting dangers.These
persons must be comprehensively informed about the hazards in their area of activity.
You must monitor their working methods in order to intervene in good time if necessary.
Product overview
Application operational area
The fans / motors are not ready-for-use products, but conceived as components for
ventilation systems (type designation Ftype label). The fans may only then be operated
when they are installed in accordance with their intended use, and safety has been
secured through protective devices in accordance with DIN EN ISO 13857 (DIN EN ISO
12100) or other structural protective measures.
Information
This assembly instructions describes the combination of motor and controller. Dependent
on application and version of the fan absolutely the resuming specications are to be
considered!
3.2
Functional description
ECblue stands for EC fans with maximum efciency. Highly efcient, electronically
switched external rotor motors with permanent magnets are used the speed of which is
controlled by the integrated controller.
The devices are constructed in accordance with the general requirement in DIN EN
61800-2 for adjustable speed electrical power systems and is intended for one-quadrant
drives.
ECblue fans in different models and sizes are described in this assembly manual.
Connection, structure and technical details depend partly on the motor size.
The three used motor sizes (B, D, G) are recognisable from the type designation.
Example for fans with motor size “B”
Axial fans type:
• F _ _ _ _-_ I _. B _._ _ _ _
L-BAL-F036-GB 1007 Index 004
Centrifugal fans type:
• RH _ _ _-_ I _. B _._ _
• GR _ _ _-_ I _. B _._ _
• ER _ _ _-_ I _. B _._ _
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Assembly instructions ECblue
3.3
3.4
Product overview
Ziehl-Abegg design criteria for long service life
The service life of devices with power electronics is decisively dependent on the ambient
temperatures. The longer electronic components are exposed to high ambient temperatures, the faster the deterioration and the more probable the failures.
The device is designed with a service life amounting to at least 40.000 h when S1
operated at full power in the maximum permissible ambient-temperature environment.
In order to achieve this, the device protects itself by active temperature management.
Transport
Attention!
• Ziehl-Abegg fans are packed in the factory in accordance with the respective,
agreed, form of transportation.
• Always observe the weight specications and the permissible carrying loads of
the means of transport.
• Transport the fan(s) either in their original packing or larger fans on the transport
devices provided (axial fans: holes drilled in support arms, wall ring plates and
motor block ; radial fans: holes drilled in the motor block, fastening brackets and
support plates) with suitable means of transport. Observe the weight specications on the rating plate.
• Wear safety showes and gloves for handling!
• Do not transport the fan by the connecting cable!
• Avoid shocks and impacts to the device during the transport.
• Avoid extreme heat or cold (temperature range for storage and transportF Technical data).
• Be on the alert for any damage to the packaging or the fan.
• Radial impellers or built-in fans type ER../GR.. are generally delivered on europallets, and can be transported using lift trucks.
• Fix pallets during transport.
• Do not stack pallets.
• Only handle with suitable hoisting gear.
• Construction ER../ GR..: Fan unit may only be lifted and transported when using
a suitable hoisting device (load spreader). Ensure sufcient cable or chain length.
• Position the lifting beam transversely to the motor axis. Pay attention to adequate
width of the lifting beam.
• Never stand underneath the suspended fan because defective transport
equipment could cause death.
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Assembly instructions ECblue
3.5
Storage
•
•
•
•
•
3.6
4
4.1
Mounting
Store the fan in the original packaging in a dry area protected from the weather
and protect it from dirt and weather until nal installation.
Do not stack pallets!
Avoid extreme heat or cold (temperature range for storage and transportF Technical data).
Inspect the motor bearings for proper operation prior to installation.
Avoid prolonged storage; we recommend a maximum of one year (consult the
manufacturer before starting if stored for longer).
Waste disposal / recycling
Disposal must be carried out professionally and environmentally friendly in accordance
with the legal stipulations.
Mounting
General notes
Attention!
• Installation are only to be performed by trained service personnel. The system
manufacturer or the machine builder is responsible that the inherent installation
and security information are harmonized with the valid standard and guidelines
(DIN EN ISO 12100 / 13857).
• Lift the fan out of the packing with a hoisting unit (lifting beam). Only use the holes
in the motor block and the fastening brackets of the fan and the hook or fastening
bracket (depending on the design of the fan) as attachment points.
• The chain/rope may not touch the fan wheel when lifting with the lifting beam.
Other damage is possible.
• Check the fan for damage, e.g. transport damage, cracks or dents or damage to
the electric cables, before assembly.
• At a weight greater than 25 kg for men / 10 kg for women, the fan should be lifted
out by two persons (according to REFA). The values may differ from country to
country.
• Do not allow drilling chips, screws and other foreign bodies to reach the device
interior!
• Prior to installing the fan, it is to be checked whether the safety zone as per DIN
EN ISO 13857 and in household appliances as per DIN EN 60335 are met. If the
installation height (danger zone) above the reference level is greater than or equal
to 2700 mm and is not reduced by auxiliary means such as chairs, ladders, work
platforms or bases on vehicles, a protection grating against accidental contact is
not necessary at the fan.
• If the fan is located in danger zone, then the manufacturer or operator shall ensure
that hazards shall be prevented by appropriare protective constuctions which
meet the requirements to DIN EN ISO 13857.
• Custom designs must suit the prevailing conditions.
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Assembly instructions ECblue
•
•
4.2
Mounting
Tighten the fastenings with the specied torques.
Any use below -10 °C is dependent on not being subjected to unusual, sudden or
mechanical loads or stresses on the material (min. ambient temperature F Technical data).
Connection lead & terminal box
Information
In demanding environments (wet areas, open air installation) all connections must
incorporate water drainage curves. To ensure that water cannot penetrate through to the
controller housing from the connections install a terminal box lower than ventilator.
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4.3
4.3.1
Mounting
Installation of axial fans
Fan designs A, D, K, S and W (without nozzles)
For attachment to xed motor ange use screws with property class 8.8 or A2-70
(stainless steel) to DIN EN ISO 4014 and provide with suitable screw locking.
Permissible tightening torques MA
Motor size
B
Thread size
D
Stainless steel A2-70, friction coefcient µges = 0.12
Screw penetration
G
M8
M10
23 Nm
40 Nm
7 Nm
17 Nm
33 Nm
≥ 1,5 x d
≥ 1,5 x d
≥ 1,5 x d
9 Nm
7 Nm
≥ 1,07 x d
M6
Property class 8.8, friction coefcient
µges = 0.12
D
M6
(Special application
with 5-pitch)
9,5 Nm
When using screws with different friction values or strength classes, different tightening
torques may be necessary.
Information
• Pay attention to a sufcient screw-in length in the motor ange.
• Motor size B: Excess screw length of max. 3 mm is permissible.
• Motor size “D” + “G”: Excess screw length not permissible and it may result in the
rotor being brushed against or blocked.
• Do not install without adequate support. Mounting surface must be even.
• In the case of a vertical motor axis, the respective lower condensation drain hole
must be open.
• Fasten the fan connecting cable using cable ties to the guard grille or motor
braces.
A minimum head gap “A” of 2 mm in all installation
positions but especially in installation position H (horizontal motor shaft) is necessary. Distortion due to
uneven surface may lead to fan failure due to brushing against the fan wheel.
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4.3.2
Mounting
Installation in an exhaust air stack, design T
Mark the mounting bracket (4) in accordance with g. 1
in the chimney (3) using a 4x90° template, drill hole
center distance “a” in accordance with the mounting
bracket (4).
gure 1
Adjustable diameter area
Fan size
min.
max.
F_063
640
660
F_071
725
745
F_080
815
835
F_091
915
935
Tighten the mounting bracket (4) and the support bracket (5) g. 2 with screws (6) only
so far that the mounting bracket and support bracket do not dig into the chimney wall (3).
Self-locking nuts (7) are used for securing the screws. The enclosed protective caps (8)
are to be pushed onto the ends of the fan supports (1), g. 2.
4
9/10
1
8
1
5
7
6
3
ai_kl_1905_1
gure 2
gure 3
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
14/39
Assembly instructions ECblue
Mounting
Feed the fan (1) into the chimney in accordance with g. 3, and center it in the mounting
bracket (4). In addition, the support is to be secured in accordance with g. 2 by using
bolts (9/10).
The four support clamps (5) are used as support eyelets for additional xings (e.g. by
standing ropes) in order to relieve the chimney of the weight of greater fans.
Installation set (Part.-No. 00291545)
Pos.
Naming
Each
1
Axial fan
-
3
Chimney
-
4
Mounting bracket
4
5
Support bracket
4
6
M8x70 screws DIN EN ISO 4014
8
7
M8 nuts DIN EN ISO 10511 self-locking
8
7a
8.4 washer DIN EN ISO 7089
8
8
Protective cap
4
9
M8x30 screws DIN EN ISO 4017
4
10
M8 nuts DIN EN ISO 10 511 self-locking
4
10a
8.4 washer DIN EN ISO 7089
4
All fastening elements made of stainless steel
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
15/39
Assembly instructions ECblue
4.4
4.4.1
Mounting
Installation of centrifugal fans
Assembly of centrifugal fans, RH design
For attachment to xed motor ange use screws with property class 8.8 to DIN EN ISO
4014 and provide with suitable screw locking.
Permissible tightening torques MA
Motor size
B
Thread size
Screw penetration
D
G
M8
M10
9 Nm
M6
(Special application
with 5-pitch)
9,5 Nm
23 Nm
40 Nm
≥ 1,07 x d
≥ 1,5 x d
≥ 1,5 x d
≥ 1,5 x d
M6
Property class 8.8, friction coefcient
µges = 0.12
D
When using screws with different friction values or strength classes, different tightening
torques may be necessary.
Information
• Pay attention to a sufcient screw-in length in the motor ange.
• Motor size B: Excess screw length of max. 3 mm is permissible.
• Motor size “D” + “G”: Excess screw length not permissible and it may result in the
rotor being brushed against or blocked.
• Do not install without adequat support. Flange and mounting bracket must be
xed at on a level surface.
• In the case of a vertical motor axis, the respective lower condensation drain hole
must be open.
• The fan must be securely mounted, with vibration dampers if necessary.
Ensure that the clearance (gap) “a” see g. between the fan impeller and the stationary housing
section is constant. Distortion due to uneven surface may lead to fan failure.
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
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Assembly instructions ECblue
4.4.2
Erecting the equipment: Design ER...-..N... / ER...-..K... / GR...
•
•
•
•
•
4.4.3
Mounting
To avoid the transference of disruptive vibrations, we recommend de-coupling the
entire plug fan to avoid sounds transmitted through solids. (Spring and/or attenuation units are not a constituent part of the standard scope of delivery). Look at
our catalogue for positioning the decoupling elements or request a dimensions
sheet stating the type designation and Part.-No.
Caution: All contact points must be xed securely. If the xing is inadequate
there is a risk of the fan overturning.
Erect in the open air only if this is expressly mentioned and conrmed in the
ordering information. There is a risk of damage to the bearings if the fan remains
stopped in a moist environment. Avoid corrosion by suitable protective measures.
Roong is required.
Making your own alterations/conversions on the fan module is unacceptable safety risk.
In the case of a vertical motor axis, the respective lower condensation drain hole
must be open.
Optimal installation distances according to for RH.. / ER fans
•
•
•
•
Distance on suction side: LA ≥ 0.5 x DSa*
Distance on the pressure side: LD ≥ 1 x DSa
Impeller blade external-diameter : Ø DSa
Housing wall distances: A = 1,8 x DSa (A = B)
* In the case of disturbance ow (per example curved pipe at the suction side, aps etc.)
LA ≥ 1 x DSa
4.5
Outdoor fans in a humid atmosphere
Information
If a fan is stationary for long periods in a humid atmosphere, it should be switched
ON for minimum of two hours every month to remove any moisture that may have
condensed within the motor.
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
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Assembly instructions ECblue
4.6
5
5.1
Electrical installation
Motorheating
To prevent a stationary ventilator in a cold environment from jamming or freezing, the
Motorheating becomes automatically active at a controller interior temperature of -19 °C.
Electrical installation
Safety precautions
Danger owing to electric current
• Work on electric components may only be carried out by trained electricians
or by persons instructed in electricity under the supervision of an electrician
in accordance with electrical engineering regulations.
• The 5 electrical safety rules must be observed!
• It is forbidden to carry out work on electrically live parts. Even after disconnection, the dc-link is still live. Always wait at least 3 minutes.
• A second person must always be present when working on energized parts
or lines who disconnects in case of emergency.
• Connect fan only to electrical circuits that can be disconnected with an allpole isolating switch.
• The device owner is responsible for the EMC of the entire plant according to
the locally applicable standards.
• Inspect electrical equipment periodically: retighten loose connections –
immediately replace damaged lines and cables.
5.2
Connection
Information
The respective connections are represented in the enclosure of this assembly
instructions (F Connection diagram)!
L-BAL-F036-GB 1007 Index 004
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Assembly instructions ECblue
5.2.1
Electrical installation
Motor size “B”
Fans with cable connection (type: _ _ _ _ _-_ I _. B _._ _ _ _)
3
17.11.2009
v_anschl_ecblue_096.vsd
0.6 m
0.6 m
WH = A1 Tacho Out OC
YE = E1 Analog In
GY = A2 Status Out OC
BU = GND
GN = D1 Digital In
WH = 14
WH = 11
BN = L1
BU = N
GNYE = PE
1
2
3
1
RD = 10 V DC Out
2
Connection line and relay: light plastic-sheathed cable 18 AWG (length ca. 0.6 m)
Connection control: light plastic-sheathed cable 22 AWG (length ca 0.6 m)
Connection cover
Information
An exchange of the motor / fan should always take place with the connection leads!
The connection cover may not be opened!
•
•
•
The leads in this illustration are assigned to terminal designations with reference
to their function. Some of these are used in the following chapters.
Extension through separate connecting box for each connecting line only.
Connecting boxes and connectors are not included in the package contents.
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Assembly instructions ECblue
5.2.2
Electrical installation
Motor size “D” and “G”
Digital In
2 4V 1 0V GND D 1
Analog In
(0...10 V / PWM)
Vo r N ä ss e
u n d S c hm u tz s c h ü tz e n
K ee p d r y a n d
p r o te c t f r o m d ir t
DC Out
(Imax 10 mA)
1 3 6 0 -3 6 0
DC Out
(Imax 70 mA)
Fans with connection box (type: _ _ _ _ _-_ I _. D _._ _ _ _), (type: F _ _ _ _-_ I _. G _._
_ _ _)
K o n ta k t b e l a s t u n g
C o n t a c t r a ti n g
m a x. A C 2 50 V 2 A
E1
1
L2
L3
L2
L 3/N
L1
N
14
PE
PE
L1
Ne tzs pannu ng
Lei stung ssc hil d
L ine v olta ge
R atin g-plat e
3~ Typ nich t für IT- N etz
g e e ig n e t
3~ ty pe not sui table for IT
n e tw o r k
6
+ 24 V
+ 10 V
G ND
D1
E1
L1
K1
11
3~
N a c h E N 5 0 17 8 is t b e i V e r w e n d u n g
e in e s F I- S c h u t zs c h a lte r s e in a lls t r o m se n s itiv e r
z w in g e n d v o r g e s c h r ie b e n
3~
f o r a n i n s t a l l a t i o n o f r. c . d p r o t e c t i o n
it s h a ll b e o b s e r v e d t ha t t hi s m u s t b e o f
u n iv e r s al - c o r r en t s e n s itiv ity in a c c o r d a n c e
w it h E N 5 0 1 7 8
5 4
7
11 14
L1 L2 L3
L1
N
PE
PE
2
1
2
3
4
5
6
7
3
26.11.2009
v_anchluss_ecblue.vsd
Cover of controller housing
3 cable glands
(3 x M16 motor size “D”, 3 x M20 motor size “G”) included
Cable entry points with plastic fastener
Mains connection
Connection alarm relay
Connection contols
Slot for add-on module
Procedure:
1. Remove the cover from the controller housing for the connection.
2. All 3 cable entry points are in a sealed condition at delivery. Remove plastic
fastener if necessary, and insert cable gland, entry points that are not used must
remain sealed!
3. Insert and connect lines correctly.
4. Attach cover of controller housing again carefully in correct position before startup.
Attention!
• Temperatures up to 85 °C can be present on the controller housing.
• To connect, always use heat resistant wires or, as an alternative, silicon tubes.
• Self-tapping screws are used for the “PE” conductor connection. These cannot be
loosened and sufceintly retightened innitely.
• Remants from installation und foreign object may not remain on the inside!
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
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Assembly instructions ECblue
Electrical installation
Permissible tightening torques MA
Thread size
Tightening tor- Remark
que MA
Cable gland
M16
2.5 Nm
Sealing area for cable diameter 4…10 mm
Cable gland
M20
4 Nm
Sealing area for cable diameter 6…12 mm
Locking screw
M16 + M20
1.25 Nm
Phillips screwdriver
Locking screw
Flat screwdriver
M16 + M20
2.5 Nm
Cover of controller
housing
M4
2.3 Nm
Protective ground
connection
M4
2.5 Nm
Add-on module
M4
1.3 Nm
Max. cross section of terminals
Mains connection: L1, N and/ or L1, L2, L3
max. 2.5 mm2 and/or AWG12
Connection control: +24 V, +10 V, GND, D1, E1, K1
max. 1.5 mm2 and/or AWG16
Add-on modules:
1.5 mm2 (0.75 mm2 with wire end sleeve)
and/or AWG16
5.3
5.4
5.4.1
EMC-compatible installation of control lines
Pay attention to sufcient distance from powerlines and motor wires to prevent interferences. The control cable may not be longer than 30 m. Screened control cables must be
used when the cable length is longer than 20 m. When using a shielded cable connect
the shielding to one side only, i.e. only to the device with the protective ground (keep
cable short and with as little inductance as possible!).
Mains connection
Line voltage for 1~ types
Mains connection: PE, L1, and N. Here, it must be strictly observed that the mains
voltage lies within the allowable tolerance specications (F technical data).
Alternatively a supply of DC voltage is possible (F Technical data).
The polarities on “L1” and “N” are irrelevant.
5.4.2
Line voltage for 3~ types
Mains connection: PE, L1, L2 and L3. Here, it must be strictly observed that the mains
voltage lies within the allowable tolerance specications (F technical data).
Alternatively a supply of DC voltage is possible (F Technical data).
Connect to any two terminal clips for “L1”, “L2” and “L3”, the polarity is irrelevant.
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Assembly instructions ECblue
Electrical installation
Danger owing to electric current
Not suitabble for IT network!
5.4.3
Required quality attributes for the mains voltage
Danger owing to electric current
The mains voltage must comply with the DIN EN 50160 quality characteristics and
the dened standard voltages in IEC 60038!
5.5
Residual-current-operated protective device
For 1 ~ fan types
Residual current circuit breaker (type A)
To ensure as high a degree of reliability as possible we recommend a release current of 300
mA, where a residual current circuit breaker (type A) is used.
Danger owing to electric current
Exception: Mains connection between two phase conductors for supply networks 3 ~
230 V
For an installation of r.c.d. protection, it shall be observed that this must be of
“universalcurrent sensitivity”. In accordance with EN 50 178, Section. 5.2. other types of
current-operated protective devices may not be used.
For 3 ~ fan types
Residual current circuit breaker (type B)
Danger owing to electric current
For an installation of r.c.d. protection, it shall be observed that this must be of
“universal-current sensitivity”. In accordance with EN 50 178, Section. 5.2. other
types of current-operated protective devices may not be used. To ensure as high a
degree of reliability as possible , we recommend a tripping current of 300 mA.
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Assembly instructions ECblue
5.6
5.7
Electrical installation
Motor protection
Integrated overload protection, preceding motor protection device unnecessary (max.
prefusing FTechnical details).
Analog input (0...10 V) for setting fan speed
The unit has an analog input 0...10 V for setting fan speed.
Connection “GW E1 Viive” / “GND” (Analog In 1).
Alternatively speed setting with a PWM-signal is possible.
Attention!
Ensure correct polarity!
Never apply line voltage to analog inputs!
Possibilities for speed setting
GND
•
•
E1
+
•
0...10 V
10V GND
Control via external setting signal 0...10 V
By external wiring with a resistor (499 Ω / 0,25 W) between the
terminals “E1” and “GND” parallel to the input signal, activation
with a 0...20 mA signal is possible.
The “AM-Modbus” communication module enables a inverted
set-point signals to be programmed (10...0 V).
E1
•
Speed setting by 10 kΩ potentiometer at terminals “+10 V” and
“GND” pick-off at terminals “E1”.
•
Control by external setting signal PWM (connection “24 V” only
for motor sizes “D” and “G” available).
10 kΩ
E1
E1
GND
10 V
24V 10V GND
-
E1
GND
24 V
PWM
f = 1...10 kHz
E1
10 kΩ
+
15...28 V
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Assembly instructions ECblue
Electrical installation
Diagram Setting signal and fan speed (Idealized principle diagram)
nM
100 %
Si
0
0
1
10
2
20
3
30
4
40
5
50
6
60
7
70
8
80
9
90
10
100
0 – 10 V
0 – 100 % PWM
20.04.2009
v_nmotor@0_10v_pwm.vsd
nM Fan speed
Si Speed setting signal 0...10 V / 0...100 % PWM
5.8
5.9
Output voltage +10 V
Voltage supply e.g. for speed setting by external potentiometer.
Connection: “DC Out” - “GND” (Imax 10 mA).
It is not permissible to connect outputs of several devices to each other!
Voltage supply for external devices, only motor sizes “D”, “G”
(+24 V, GND)
Integrated voltage supply for external devices. Terminals “+ 24 V”(FTechnical data).
It is not permissible to connect outputs of several devices to each other!
During an overload or short-circuit (24 V - GND), the control voltage (and thus the device)
is disconnected . Automatic start after elimination of the cause of error.
5.10
Enable, device ON / OFF (Digital In 1 = D1)
Electronic disconnection and Reset after fault via oating contact at terminals
“D1” - “+24V” / “+10V”
• Device “ON” for closed contact.
• Controller “OFF” with opened contact.
• Relais “K1” remains energized, connections 11 - 14 bridged.
For motor size “D”,“G” the signal lamp ashes in code |1 | (FDiagnostics / Faults).
Attention!
• No disconnection (isolation) when turned off by remote, in accordance with
VBG4 §6)!
• Never apply line voltage to the digital input!
• It is not permissible to connect inputs of several devices to each other!
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Assembly instructions ECblue
5.11
5.12
Electrical installation
Relay outputs (K1)
An external fault indicator is available over the potential-free contact of the built-in relay
(max. contact rating FTechnical data and connection diagram).
For operation the relay is energized, connections “11” and “14” are bridged. For fault the
relay is de-energized (FDiagnostics / faults).
When switching off via enable (D1 = Digital In 1), the relay remains energized.
Tacho out
In motor size “B” a frequency signal can be output at output “A1 Tacho Out OC”. This
signal serves to evaluate the current speed of the fan.
(Functional description obtainable from the Ziehl-Abegg Support Department F Service
note)
In engine size “D” and “G” the tachometer output is on the additional module “AMMODBUS”.
Via the output “A2 Status Out OC” an additional operating message is possible in
motor size “B”.
The OC (Open-Collector) output is on GND potential during operation. When
using the output voltage “+10 V” a LED can be controlled by a pull-up resistor (>
4.7 kΩ).
Status
Out OC
Output Status Out OC (motor size “B”)
DC Out
5.13
10V
A2
Pull Up
01.03.2010
v_ecblue_096_status_out_led.vsd
5.14
5.15
Potential at control voltage connections
The control voltage connections (< 50 V) relate to the joint GND potential (Exception:
Relay contacts are potential free). There is a potential separation between the control
voltage connections and the earthed conductor. It must be ensured that the maximum
external voltage at the control voltage connections cannot exceed 50V (between “GND”
terminals and “PE” earthed conductor). If necessary, a connection to the earthed conductor potential can be established, install bridge between “GND” terminal and the “PE”
connection (terminal for screening).
Add-on modules
The assembly instructions available here describe the “basic version”.
If required, an auxiliary module can be retrotted to the designated slot for motor size
“D”, “G”. The auxiliary module is installed automatically. Manual installation or parameterisation is not required!
For fans of motor size “B” separate versions with integrated add-on modules are
available.
The extended scope of function is specied in the documentation for the auxiliary
module.
L-BAL-F036-GB 1007 Index 004
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Assembly instructions ECblue
Start-up
The range of additional modules is constantly being extended and adapted to market
requirements. The currently available additional modules can be requested from ZiehlAbegg.
Examples for currently available additional modules
6
6.1
Type
Part.-No.
Function
AM-MODBUS
(for motor size “D”
and “G”)
349045
Communication module
Over the “AM-MODBUS” module can be communicated with
the controller of the fan. The module can be put in temporarily
for programming of desired functions during start-up or for
diagnostics. The connection to the control terminal is made by
a connecting cable or wirelessly by means of radio.
The module is left in the slot if it is to be integrated into a
module bus system or networked to several devices. The
addressing of ECblue fans takes place automatically, i.e. it is
not necessary to manually enter individual network addresses
for each fan.
AM-PREMIUM
(for motor size “D”
and “G”)
349046
Premium Module
When the “AM-PREMIUM” is plugged in the controller in the
fan is extended to become a full-grade multipurpose controller.
The “Premium module” provides not only an integrated module
bus interface, it also enables sensors to be connected straight
to the fan.
The module also comes with two analogue inputs and one
analogue output.
Start-up
Prerequisites for commissioning
During commissioning, unexpected and hazardous conditions can arise in the entire
installation due to defective adjustments, defective components or incorrect electrical
connections. Remove all persons and objects from the hazardous area.
Attention!
• Before rst-time start-up, check the following:
1. Installation and electrical connection have been properly completed?
2. Has any leftover installation material and other foreign material been removed
from the fan area?
3. That safety devices -if necessary- are mounted (EN ISO 13857)?
4. The impeller is out of reach?
5. Installation position and the arrangement of condensation water drains
correspond to each other?
6. Connection data complies with the specications on the type plate?
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Assembly instructions ECblue
•
7
7.1
Diagnostics / Faults
Commissioning may only take place if all safety instructions have been
checked and danger can be excluded.
– Check the direction of rotation (F rotation direction arrow on the fan blade,
impeller base plate or on the fan housing).
– Check for quiet, low vibration operation. Strong vibrations due to erratic
operation (unbalanced), e.g. caused by transportation damage or improper use,
can lead to failure.
– A-rated sound power levels of over 80 dB(A) are possible, see product
catalogue.
– Check for mechanical vibrations after installation into the system. If the
tolerances according to DIN Iso 10816-1 are exceeded, it is possible to exclude
certain speed ranges (F Motor Setup or add-on module).
Diagnostics / Faults
Trouble shooting
Type of error
Possible cause
Remedial measures
Fan does not run
(anymore)
Failure line voltage
Failure of one phase
Under - or overvoltage
check line voltage
Shortcut Earth
Check motor connection and line voltage
fan will not start
Short circuit winding
Replace fan
Thermal motor protection
has triggered (motor is
overheated)
Check for free air passages; remove foreign bodies if
necessary
F "Impeller blocked or dirty"
Check temperature of supply air
chec voltage
Impeller blocked or dirty
- Switch off power to the motor and secure against
switching back on
- heck safe isolation from supply
- Remove safety grille
- Remove foreign bodies or soiling
- Remount the safety grille
- Further procedure as in the chapter “Start-up”
Temperature too low for
bearing grease
Insert bearing with cold greasing
Air stream wrong direction Check air stream
(Motor turns in wrong direction at high speed)
F "Fan does not run"
Fan turns too slowly Impeller / blade scrapes /
brushes
L-BAL-F036-GB 1007 Index 004
Clear foreign bodies/dirt from the fan
Part.-No. 00295296-GB
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Assembly instructions ECblue
Type of error
Air ow to low
Vibrations
Unusual noises
Diagnostics / Faults
Possible cause
Remedial measures
Active temperature management effective
(Motor or electronics overheated)
Check for free air passages; remove foreign bodies if
necessary
F "Impeller blocked or dirty"
Check temperature of supply air
Check installation space (air speed over heat sink)
Fan turns too slowly
F
Airways blocked
Check for free air passages (supply/exhaust air vents,
lters)
F "Impeller blocked or dirty"
Pressure loss different to
planned
Check fan selection
Imbalance
Check blades for damage, soiling or ice F "Impeller
blocked or dirty"
No or wrong vibration
dampers (only in radial)
Install correct vibration dampers
Bearing damaged / worn
Change bearings
Impeller / blade scrapes /
brushes
Clear foreign bodies / dirt from the fan F "Impeller
blocked or dirty"
Operation beyond stall
point
(for axial fans)
Check for free air passages (supply/exhaust air vents,
lters)
Wrong overlap on nozzle
(for centrifugal fans)
Observe the installation instructions
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Assembly instructions ECblue
7.2
Diagnostics / Faults
For motor size “D” and “G” Status LED with ash code
OFF
ON
1x
2x
3x
4x
5x
6x
7x
23.04.2009
v_led_status_ecblue.vsd
8x
9x
11.02.2009
v_flash_explain.VSD
Relays K1
LED Code
(for function fac(only D, G)
tory setting)
Cause
Explanation
Reaction of Controller
Adjustment
Line voltage available?
Unit switches OFF and automatically
ON when the voltage has been restored
OFF
de-energized, 11
no line voltage
- 14 interrupted
ON
energized, 11 - 14
Normal operation without fault
bridged
1x
no enable = OFF
energized, 11 - 14
Switch OFF by external contact (F
bridged
Terminals “D1” - “24 V / 10 V” (Digital digital input).
In 1) not bridged.
2x
Active temperature management
The device has an active temperature managementto protect it from
damage due to too high inside temperatures. In case of a temperature
rise above the xed limits, the modu- At sinking temperature the modulaenergized, 11 - 14
lation is reduced linearly. To prevent tion rises again llinear.
bridged
the complete system being switched Check cooling of the controller
off externally (in this operation permissible for the controller) in case of
reduced operation due to too high an
internal temperature, no fault message is sent via the relay.
3x
HALL-IC
de-energized, 11
Incorrect signal from the Hall-ICs,
- 14 interrupted
error in the commutation.
L-BAL-F036-GB 1007 Index 004
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Controller turns the motor off. Automatic restart if no more fault is recongized.
Assembly instructions ECblue
Relays K1
LED Code
(for function fac(only D, G)
tory setting)
Diagnostics / Faults
Cause
Explanation
Reaction of Controller
Adjustment
Line failure (only for 3 ~ types)
The device is provided with a built-in
phase-monitoring function for the
mains supply. In the event of a mains
de-energized, 11
interruption (failure of a fuse or
- 14 interrupted
mains phase) the unit switches off
after a delay (approx. 200 ms).
Function only when load for the controller is high enough.
Following a shutoff, a startup attempt
is made after approximately 15 seconds, if the voltage supply is high
enough. This keeps occurring until
all 3 supply phases are available
again.
Checking power supply
Motor blocked
de-energized, 11 If after 8 seconds cummutation no
- 14 interrupted
speed is measured > 0, the fault
“Motor blocked” is released.
EC-Controller switches off, renewed
attempt to start after about 2.5 sec.
Final shutoff, when fourth starting
test fails. It is then necessary to have
an enabling reset or to disconnect
the power supply.
Check if motor is freely rotatable.
6x
IGBT Fault
de-energized, 11
Shortcut earth or shortcut of motor
- 14 interrupted
winding.
EC-Controller switches off, renewed
attempt to start after about 60 sec. F
Code 9
Final shutoff, if - following a second
starting test – a second fault detection is detected within a period of 60
seconds.
It is then necessary to have an enabling reset or to disconnect the
power supply.
7x
If the intermediate circuit voltage
rises again within 75 seconds above
DC undervoltage
the limit, an automatic starting test is
run.
de-energized, 11 If the intermediate circuit voltage
drops below a specied limit, the de- If the intermediate circuit voltage re- 14 interrupted
vice is shutoff.
mains below the limit for more than
75 seconds, the device is shutoff
with a fault message.
8x
DC overvoltage
If the intermediate circuit voltage inde-energized, 11 creases above the specied limit the
motor is switched off.
- 14 interrupted
Reason for excessively high input
voltage or alternator motor operation.
9x
IGBT cooling down period
IGBT cooling down period for approx.
energized, 11 - 14
60 sec.
bridged
Final shutoff after 2 cooling-off intervals F Code 6
4x
5x
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
30/39
If the intermediate circuit voltage
drops again within 75 seconds below
the limit, an automatic starting test is
run.
If the intermediate circuit voltage remains above the limit for more than
75 seconds, the device is shutoff
with a fault message.
Assembly instructions ECblue
8
8.1
Service work
Service work
Repairs / maintenance
Attention!
• Allow maintenance work to be carried out by trained specialists only.
• Please observe the safety regulations and the worker´s protection rules by
all maintenance and service work (DIN EN 50 110, IEC 364).
• Before working on the fan, this must be disconnected from the power supply
and secured against switching back on!
• Keep the airways of the fan free - danger because of objects dropping out!
• No maintenance work at running fan!
• Watch out for vibration free motion!
• Depending on the application and the transfer medium the impeller has a
natural wear. Deposits on the impeller can lead to imbalance and thus to
damages (danger of endurance fracture). The impeller can disintegrate!
• Maintenance interval in accordance with the degree of contamination of the
impeller!
• In case of imbalance: Rebalancing the impeller.
• Check the impeller, in particular the weld-seams, for possible cracks.
• Repair, e.g. by welding is prohibited!
• The fan or motor is maintenance free through the usage of ball bearings with “lifetime lubrication”. After the end of the grease service-life (ca. 30-40,000 h during
standard usage), an exchange of the bearing is necessary. For this as well as for
all other defects (e.g. on the winding or in the electronics), please contact our
service department.
• Bolted-on wheels and/or wings may only be replaced by authorised Ziehl-Abegg
AG staff. The manufacturer shall not be liable for damage caused through
improper repair work.
• Regular inspection, and cleaning is necessary to prevent imbalance due to ingress
of dirt.
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
31/39
Assembly instructions ECblue
8.2
Enclosure
Cleaning
Danger owing to electric current
Voltage supply for motor must be interrupted and secured against restoration!
Attention!
• Do not use any aggressive, paint solvent cleaning agents when cleaning.
• Cleaning with a water jet:
– Make sure that no water gets into the inside of the motor, note protection class
(IP).
– Do not hold the jet spray directly on the motor openings and seals.
– During cleaning work using a jet spray, no guarantee is assumed regarding
corrosion formation / paint adhesion for unpainted / painted fans.
– After the cleaning process, the fan must be operated for 30 minutes at 80 to
100 % of maximum speed for drying purposes!
9
9.1
Enclosure
Technical data
Line voltage*
(F Rating-plate)
AC: 1 ~ 200...277 V (+/- 10 % ),
50/60 Hz
DC: 280...400 V (+/- 10 % )
AC: 3 ~ 200...240 V (+/- 10 % ),
50/60 Hz
DC: 280...340 V (+/- 10 % )
AC: 3 ~ 380...480 V (+/- 10 % ),
50/60 Hz
DC: 500...680 V (+/- 10 % )
DC supply not UL® approved!
Maximal line fuse
16 A for all types 1 ~ and 3 ~
Max. cut-in current
126 A
Max. load limit integral of cut-in
current
1.22 A2s
Clock frequency
16 kHz
Input resistance for signal set for Ri > 100 kΩ
the rotational speed
Specication speed setting sig- Voltage: 15...28 VDC
nal PWM
Switching Frequency: 1...10 kHz
On-off ratio: 0...100 %
Voltage supply for external devi- + 10 V, I max 10 mA (short-circuit-proof)
ces
+24 V ±20 %, Imax 70 mA (only for motor size “D”, “G”)
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
32/39
Assembly instructions ECblue
Enclosure
Permissible minimal and maxi- -25 °C...60 °C (up to 70 °C **)
mal ambient temperature for op- Please see the technical documentation of the product for the minimum
eration
and maximum ambient temperature valid for the respective fan; These
may deviate from the specied permissible ambient temperatures.
To avoid condensation, the drive must be connected permanently to the
mains.
Max. permissible installation
height
height 1000 m amsl without derating
Permissible rel. humidity
85 % no condensation
Permissible temperature range
for storage and transport
-30...+80 °C
Electromagnetic compatibility for Interference emission EN 61000-6-3 (domestic household applications)
the standard voltage 230 / 400 Interference immunity EN 61000-6-2 (industrial applications)
V according to DIN IEC 60038
Harmonics current according
For 1 ~ types
Active power factor adjustment for sinusoidal input current (PFC = Power
- Factor - controller), harmonic current in accordance with EN 61000-3-2
are guaranteed.
For 3 ~ types
EN 61000-3-2 for a “professional unit”.
Please ask Ziehl-Abegg for the individual harmonic oscillation levels of
the current as a percentage of the fundamental oscillation of the rated
current.
Contact rating of the internal
relay
AC 250 V 2 A
Max. leakage current according < 3.5 mA
to the dened networks of DIN
EN 60990
dB(A) values
F product catalog
Protection class of motor according DIN EN 60529
IP 54
* Regarding the mains connection, the devices are to be classied as category “C2” devices
according to the relevant DIN EN 61800-2 The increased requirements placed on electrical
interference for category “C1” devices are complied with in addition.
** In case of a temperature increase above the predetermined threshold values modulation is
linearly reduced by active temperature management.
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
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Assembly instructions ECblue
9.2
Enclosure
Connection diagram
Motor size “B” (type: _ _ _ _ _-_ I _. B _._ _ _ _)
GND
B
ID
A
GND
B
ID
2
A
E1 Analog In 1
Signalanschluss
Signal connection
WH
A1 Tacho/Error Out OC
A2 Status Out OC
YE
GND
GY
RD
14
WH
11
WH
L1
BN
N
BU
GNYE
PE
D1 Digital In 1
K1
BU
5
Kontaktbelastung
Contact rating
max. AC 250 V 2 A
GN
10 V DC Out (Imax = 10 mA)
ECblue (_ _ _ _ _-_I_.B_._ _ _ _)
+
PE N
Eingang
Input
0...10 V
L1 11 14
Netz
Line
1 ~ 200...277 V
50/60 Hz
10 kΩ
1
Externe Drehzahlvorgabe
External speed setting
E1
GND
10 V
3
GND
E1
10 kΩ
-
+
15...28 V
PWM
f = 1...10 kHz
4
1
2
3
4
5
Line voltage 1 ~ 200...277 V, 50/50 Hz
Signal connection
Input 0...10 V
PWM input, f = 1...10 kHz
Contact rating max. AC 250 V 2 A
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
34/39
KT00044A
11.03.2010
Assembly instructions ECblue
Enclosure
Motor size “D” and “G” (type: _ _ _ _ _-_ I _. D _._ _ _ _), (type: _ _ _ _ _-_ I _. G _._ _ _ _)
Analog In 1
E1
DC Out
24V 10V GND D1
DC Out
Digital In 1
(Imax = 70 mA)
(Imax = 10 mA)
ECblue (_ _ _ _ _-_I_.D_._ _ _ _), (_ _ _ _ _-_I_.G_._ _ _ _)
2
Kontaktbelastung
Contact rating
max. AC 250 V 2 A
L1
11
14
L1
N
L2
L3
K1
PE
Externe Drehzahlvorgabe
External speed setting
PE L1 L2 L3/N
Netzspannung
Line voltage
10 kΩ
Leistungsschild
Rating-plate
3 ~ Typ nicht für IT-Netz geeignet
3 ~ type not suitable for IT network
3
1
+
GND
10 V
4
E1
Eingang
Input
0...10 V
24 V
PWM
f = 1...10 kHz
E1
10 kΩ
5
-
E1
GND
MOEA03K0
11.03.2010
+
15...28 V
1
2
3
4
5
Line voltage F Rating-plate (3 ~ type not suitable for IT network)
Contact rating max. AC 250 V 2 A
External speed setting
Input 0...10 V
PWM input, f = 1...10 kHz
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
35/39
Assembly instructions ECblue
9.3
EC Declaration of Incorporation
EC Declaration of Incorporation
as dened by the EC Machinery Directive 2006/42/EC,
Annex II B
ZA87-GB-12/09 Index 000
00296702-GB
The design of the incomplete machine:
• Axial fan FA.., FB.., FC.., FE.., FS.., FT.., FH.., FL.., FN.., VR.., VN..
• Centrifugal fan RA.., RD.., RE.., RF.., RG.., RH.., RK.., RM.., RR.., RZ.., GR..,
•
ER..
Cross ow fan QK.., QR.., QT.., QD.., QG..
Motor type:
• Induction internal or external rotor motor (also with integrated frequency inverter)
• Electronically commutated internal or external rotor motor (also with integrated EC
controller)
complies with the requirements in Appendix I, Articles 1.1.2, 1.1.5, 1.4.1, 1.5.1 in
EC Machinery Directive 2006/42/EC.
The manufacturer is theZiehl-Abegg AG
Heinz-Ziehl-Straße
D-74653 Künzelsau
The following standards are applied:
EN 60204-1:2006 Safety of machinery; electrical equipment of machines; Part 1: General requirements
EN ISO
Safety of machinery; basic concepts, general principles for design
12100:2003
EN ISO
Safety of machinery; safety distances to prevent danger zones being
13857:2008
reached by the upper limbs
Note:
The maintenance of the EN ISO 13857:2008 relates only to the
installed accidental contact protection, provided that it is part of the
scope of delivery.
The specic technical documentation in accordance with Appendix VII B has been
written and is available in its entirety.
The person authorised for compiling the specic technical documentation is: Dr. O. Sadi,
address see above.
The specic documentation will be transmitted to the ofcial authorities on justied
request. The transmission can be electronic, on data carriers or on paper. All industrial
property rights remain with the above-mentioned manufacturer.
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
36/39
Assembly instructions ECblue
EC Declaration of Incorporation
It is prohibited to commission this incomplete machine until it has been secured
that the machine into which it was incorporated complies with the stipulations of
the EC Machinery Directive.
Künzelsau, 29-Dec-2009 Dr. O. Sadi - Technical Manager Ventilation
Technology
i.V.
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
37/39
Assembly instructions ECblue
9.4
Index
B
Bearing
R
28, 31
C
Chimney
15
cleaning
32
Clock frequency
32
condensation drain hole
13, 16
control cable
21
current-operated protective
devices
22
D
DC voltage
21
relay
Relay outputs
Reset
Residual current circuit
breaker
Setting signal
Technical data
temperature management
24
28
32
L
leakage current
33
M
motor size
Motorheating
9
18
O
one-quadrant
Outdoor fans
9
17
P
PWM-signal
L-BAL-F036-GB 1007 Index 004
24
T
I
Imbalance
Input resistance
22
S
E
Enable
25
25
24
23
Part.-No. 00295296-GB
38/39
2, 32
29
Assembly instructions ECblue
9.5
Index
Manufacturer reference
Our products are manufactured in accordance with the relevant international regulations.
If you have any questions concerning the use of our products or plan special uses,
please contact:
Ziehl-Abegg AG
Heinz-Ziehl-Straße
74653 Künzelsau
Telephone: +49 (0) 7940 16-0
Telefax: +49 (0) 7940 16-504
[email protected]
http://www.ziehl-abegg.de
9.6
Service information
If you have any technical questions while commissioning or regarding malfunctions,
please contact our V-STE support department for control systems - ventilation technology.
Our worldwide contacts are available in our subsidiaries for deliveries outside of Germany. F www.ziehl-abegg.com.
If you make returns for inspections or repairs we need certain information in order to
facilitate focused trouble shooting and fast repair. Please use our repair tickets for this. It
is provided to you after you have consulted our support department.
In addition, you can download it from our homepage. Download - Ventilation Technology
- Topic: Control Engineering - Document type: General documents.
L-BAL-F036-GB 1007 Index 004
Part.-No. 00295296-GB
39/39
INSTALLATION INSTRUCTIONS
And Maintenance Manual
Heat Module SERIES
FURNACE MODULE
ANSI Z83.8 (2006) – Gas-Fired Duct Furnace
HM Series Modules are a Recognized Furnace Component
Design Certified by Intertek Testing Services ( ETL)
For Indoor or Outdoor Installation and
Installation Downstream from Refrigeration Systems
This Product is intended for installation by Original Equipment Manufacturers
Of Listed Heating Equipment in Duct or Cabinet mounted Applications
The furnace modules covered by these instructions become a component of a “Listed” product,
Subject to the guidelines of application provided in these instructions and as
designated by the Certifying Agency in the Manufacturer’s Listing Procedure
Beckett Gas Inc
38000 Beckett Parkway
North Ridgeville, Oh. 44039
14094 Rev. 0
1
This product MUST BE INSTALLED IN A NON-COMBUSTIBLE duct and is not designed to have any portion of the heat
exchanger exposed outside the duct or cabinet in which this furnace module is housed.
A Nameplate is attached to the burner assembly to identify the model and serial number of this product. This plate must be left
attached when the module is installed in the product for identification purposes.
A Rating Plate is attached to the manifold assembly, and contains information including gas type, maximum and minimum input
rating, manifold pressure, maximum and minimum inlet gas pressure, maximum and minimum airflow requirements, output capacity
and electrical ratings for this module. This plate may be detached at assembly, provided that all the information contained on this
plate is contained on a plate affixed by the original equipment manufacturer within the vestibule area where it is readily visible when
the access panel is opened for installation or service.
This product must be applied in accordance with the requirements of its recognition, according to Tables 1 to 3. Consider maximum
input ratings, duct and cabinet clearances to heat transfer surfaces (tubes), maximum and minimum temperature rise and maximum
and minimum airflow. In addition to these specifications the Original Equipment Manufacturer of the “Listed” equipment shall
provide the following in accordance with its product listing:
Openings for combustion air must be provided in a panel or door (except separated combustion systems) with direct access to
the vestibule area where the burners and draft inducer are located. This air opening must be sized to provide a suitable supply
of air for combustion to the burner compartment and have a minimum free area as follows:
o
2
1 sq. in. (625mm ) per 4,000 Btuh (2,345 W) of rated input for total input
The minimum dimension of any air opening should not be less than 3 inches. Heating appliance must be installed so that air
access to inlet openings is unobstructed.
A vent discharge duct of minimum cross-sectional area equal to outlet area of the draft inducer.
A non –adjustable High Limit Switch to provide shut-off of the gas supply to the main burners when the outlet air reaches a
o
o
temperature not in excess of 250 F (121 C)
Adequate airflow within the duct or cabinet, sufficiently well distributed to limit the maximum temperature above inlet air
temperature on heat exchanger surfaces as follows:
o
1030 F
o
1080 F
o
1330 F
o
1430 F
o
(572 C)
o
(600 C)
o
(739 C)
o
(794 C)
Clearances to combustibles as appropriate for the design, but in no case less than the following unless determined by test as
part of the manufacturer’s listing:
Aluminized Steel …………….
409 Stainless Steel ………….
439 Stainless Steel ………….
304 Stainless Steel ………….
Sides and back ……………………….
Bottom …………………………………
Top …………………………………….
Front ……………………………………
Vent pipe to any combustible surface
6 in. (152mm)
2 in. (51mm)
6 in. (152mm)
36 in. (914mm)
6 in. (152mm)
o
o
Modules may be installed in series provided that the discharge Air Temperature does not exceed an average of 160 F (89 C)
above Room Temperature.
The final determination of the safety and suitability of this product for the specific application shall be the responsibility of the
manufacturer of the “Listed” equipment and the listing Agency.
General Information to include in Installation and Operating Instructions
The “Listed” equipment manufacturer’s Installation and Operating Instructions shall provide all necessary information as required by
ANSI Z83.8 – CSA 2.6M and or ANSI Z21.47- CSA 2.3-2003 for the application, including but not limited to the following; Installation
Codes, Hazard Warnings, gas piping, electrical connection, Lighting Instructions, Sequence of Operation, Manual reset switches,
Wiring Diagrams, Clearance to Combustibles, Airflow and Rise ranges, Venting and troubleshooting, Minimum input rate
adjustment, and for checking the gas tightness of the safety shut-off valve(s) on at least an annual basis, as identified in the sections
of the referenced standards identified in “Instructions” and “Marking”.
2
Reference to the following information must be included in the instructions that the OEM provides with the finished product in which
the furnace module is installed.
o
All unit installations must be in accordance with the National Fuel Gas Code ANSI Z223.1 (NFPA 54) in the US and
Can/CGA-B149 Installation Code in Canada and all applicable local codes and ordinances. Requirements
o
A WARNING that the furnace is not certified or suitable for use in drying or process applications. Use in such applications
voids any warranty and manufacturer disclaims any responsibility for the duct furnace and/or application
o
A WARNING that the Gas-fired furnaces are not designed for use in hazardous atmospheres containing, flammable vapors
or combustible dust, in atmospheres containing chlorinated or halogenated hydrocarbons, or in applications with airborne
substances containing silicone.
o
A WARNING that the presence of chlorine vapors in the combustion air supply to gas fired heaters presents a substantial
corrosion hazard.
o
A WARNING: The use and storage of gasoline or other flammable vapors and liquids in the vicinity of this appliance is
hazardous.
o
WARNING labels attached to exterior of cabinet as required by Z83.8-CSA 2.6M Sections 1.32.4 and 1.32.5 and Z21.47CSA 2.3 Sections 1.24, 1.25, 1.26 and 1.27.
o
Safety, lighting, operating and shutdown instructions
o
All electrical equipment must be grounded and wired be in accordance with the National Electric Code (ANSI/NFPA 70) in
the US and the Canadian Electric Code (CSA C22.1) in Canada.
o
A statement to cover replacement wiring “ If any original wire as supplied with the appliance must be replaced, it
must be replaced with wiring material having a temperature rating of at least 90 oC (194 oF).”
Installation and Handling of Furnace Module
- WARNING –
Do not use heat exchanger tubes or manifold pipe as load bearing supports during handling or furnace module
Installation in cabinet. Severe damage may result to tubes, tube joints or burner assembly that can cause unsafe
operation, severe personal Injury, death or significant property damage.
Provide proper support or rigging using vest panel and tube support brackets to support module during installation into cabinet.
A vent duct must be provided to exhaust the flue gases to the outside of the unit. This duct must be at least the same size
o
o
(or cross-section) as the draft inducer outlet. Avoid sharp 90 bends, especially with rectangular ducts. Use 45 angles to
o
provide smoother transition. For round vent ducts, radius of the 90 should be as generous as possible. Discharge should
be located to minimize possibility of flue gas recirculation into combustion air supply.
2. Verify that electrical supply matches the voltage rating of the heat module. Refer to Rating Plate attached to assembly.
3. Carefully support and lift module into position and slide into cabinet. Fasten to cabinet.
4. Install High Limit Switch if not supplied, with proper temperature set point per Certifying Agency procedure.
5. The furnace module control system requires both line voltage and low voltage circuits with correct polarity, and clean
neutral and ground. Line voltage readings between L1 and Neutral as well as L1 and Ground should be within +/- 3 volts.
6. Complete electrical connections from module to limit switch and 24 VAC supply to ignition control.
7. Provide necessary support for wiring in vestibule. Wiring should not contact metal surfaces with may be hot during module
operation.
8. A condensate drain fitting is provided in the flue box. If module is located downstream of the cooling system, a condensate
collection trough should be provided at base of the vest panel. Attach condensate drain tube to each fitting.
9. Connect supply piping to gas valve using a pipe sealant resistant to LP gases on pipe threads. Properly support gas valve
during supply installation to prevent valve from turning or damage to burner assembly.
10. Perform electrical, operation and leak checks on assembled unit according to Certifying Agency procedures and
appropriate ANSI standards.
1.
3
Outdoor Installations
Air for Combustion
The furnace module must have an ample supply of air for proper combustion of gas. Never locate unit so that supply of air
to combustion air openings is obstructed. Combustion air openings in the cabinet should be sized to provide 1sq. in of free
area per 4000 Btu of input. Combustion air inlet and flue gas outlet must be located in the same pressure zone. Refer to
appropriate installation codes for required clearances to combustion air openings.
Venting
o
o
The venting system for outdoor units is a Category III, with vent products at positive pressure and up to 550 F (288 C).
The cross-sectional area of the vent duct or pipe must be at least equal to the discharge area of the draft inducer.
The discharge opening must always be located in the same pressure zone as the combustion air inlet. Flue gases must
be directed away from combustion air inlets, to avoid recirculation of into combustion air supply.
o
For horizontal discharge, the outlet should be located on the same side of the unit as the combustion air inlet
opening. Never locate the vent outlet on the opposite side from the combustion air inlet opening. Vent duct should
extent about an inch past the cabinet, to minimize the potential of recirculation. Vent duct should be pitched down
toward the outlet to insure proper drainage. Duct opening should be protected by a ½ in. x ½ in. (12mm x 12mm)
mesh screen. A rain cap or cover may be used over the discharge opening, but should not intersect the flue gas
discharge path. See Fig. 1 below.
o
For horizontal discharge where flue gases need to be vented vertically, the preferred flue gas discharge should
terminate in an exterior flue riser that extends at least to the top of the cabinet and is open at top and bottom. This
riser must be located on the same side of the appliance as the combustion air inlet opening. An open riser should
never be located in the appliance vestibule as this could result in recirculation of flue gases into the combustion air
supply for the burners. See Fig. 2 below.
o
For vertical discharge, employ a 90o elbow and sufficient vent pipe so that the vent terminates at least 1 to two
feet above the cabinet. An approved rainproof vent cap must be applied to the termination.
o
For Flue vent sizing consult the National Fuel Gas Code.
Figure 1 – Horizontal Discharge Vent
4
Figure 2 – Vertical Venting- Exterior Flue Riser
Draft
Inducer
Cabinet
4 ft. (1.2m)
Min
6 in. (152mm)
diameter Min.
Relief opening and
combustion air opening into
vestibule must be at least 1ft.
above snow line
Vent
Duct
Open at base of
tube or riser
Indoor Installations
Air for Combustion
The furnace must be installed in a location with adequate clearances to provide for an adequate combustion air space,
service and inspection, and proper clearances from combustible construction. The furnace shall be located in such a
manner that it does not interfere with the circulation of air in the heated space.
All fuel burning equipment must be supplied with air that enters into the combustion process and is then vented outdoors.
Sufficient air must enter the appliance location to replace the air exhausted through the vent system. Do not install
appliance in a confined space without providing wall openings to and from this space, if building construction is such that
the normal infiltration does not provide sufficient air for combustion and venting, outside air must be introduced. Install air
openings that provides a total free area in accordance with the following:
2
1.
Air from inside the building – Opening of 1 sq. in. (645mm ) per 1,000 Btuh (293 W) of input, but never less than 100
2
sq. in. (.06 m )
2.
Air from outside (ducted) – Opening of 1 sq. in. (645mm ) Per 2,000 Btuh (586 W)
3.
Air from outside (direct opening) – Opening of 1 sq. in. (645mm ) per 4,000 Btuh (1172W)
2
2
Venting
All furnace modules must be vented outside of the heated space.
The furnace must be connected to a factory built chimney or vent complying with a recognized standard or a masonry or
concrete chimney lined with a lining material acceptable to the authority having jurisdiction.
The furnace modules will be classified in accordance with ANSI standards as follows:
o
Category 1 – Non-condensing appliance with negative vent pressure
5
Category 3 – Non-condensing appliance with positive vent pressure
o
(See Figure 3)
Vertically Vented Furnaces – Category I
1.
Use single wall or double wall (Type B) vent pipe of diameters listed in the following table for the appropriate models.
2.
Maximize the height of the vertical run of vent pipe. A minimum of five (5) feet (1.5m) of vertical pipe is required. The
top of the vent pipe must extend at least two (2) feet (0.61m) above the highest point on the roof. (Use Listed Type B
vent for external runs). An approved weatherproof vent cap must be installed to the vent termination.
3.
Horizontal runs must not exceed 75% of the vertical height of the vent pipe, up to a maximum of ten (10) feet (3m).
Horizontal runs should be pitched upward ¼” per foot (21mm/m) and should be supported at 3 foot (1m) maximum
intervals.
4.
Design vent pipe runs to minimize the use of elbows. Each 90o elbow is equivalent to 5 feet (1.5m) of straight vent
pipe run.
5.
Vent pipe should not be run through unheated spaces. If such runs cannot be avoided, insulate vent pipe to prevent
condensation inside vent pipe. Insulation should be a minimum of ½” (12.7mm) thick foil faced fiberglass, minimum 1½
# density.
6.
Dampers must not be used in vent piping runs. Spillage of flue gases into the occupied space could result.
7. Vent connectors serving Category 1 heaters must not be connected into any portion of a mechanical draft system
operating under positive pressure.
National Fuel Gas Code Venting Pipe requirement
75,000-149,999
15,000-400,000
Use 5-inch pipe
Use 6 Inch pipe
Figure 3
Vertical Venting – Category I
6 Ft. Min.
(1.8m)
Approved Vent Cap
Type B Vent Pipe
2 Ft. Min.
(0.61m)
10” Max. (245mm)
Clearance specified on Vent Pipe
Thimble
5 Ft. Min.
(1.52m)
¼ in.
(6mm)
Adjacent
Building
6” (152mm) Min. from pipe to ceiling
1 Ft.
(305mm)
10 Ft. Min.
(3.05m)
Heating Appliance
6
Roof
Horizontally Vented Furnaces -Category III
(See Figure 4)
Pressures in Category III venting systems are positive and therefore care must be taken to avoid flue products from
entering the heated space. Use only vent materials and components that are UL listed and approved for Category III
venting systems.
WARNING: Do not use Type B vent within a building on horizontally vented units.
All vent pipe joints must be sealed to prevent leakage into the heated space. Follow instruction provided with approved
venting materials used. The proper vent pipe diameter must be used, to insure proper venting of combustion products, as
follows:
•
Input ratings of 150,000 Btuh (43,960 W) to 400,000 Btuh (117228 W) -
6 in. diameter (152mm)
•
Input ratings of 75,000 Btuh (21,980 W) to 149,999 Btuh (43,958 W) –
5 in. diameter (126mm)
The total equivalent length of vent pipe must not exceed 50 ft. (15.25m). Equivalent length is the total length of straight
sections, plus 5 ft. (1.52m) for each 90o elbow and 2.5 ft (0.76m) for each 45o elbow.
The vent system must also be installed to prevent collection of condensate. Pitch horizontal pipe runs downward ¼ in. per
foot (21mm per meter) toward the outlet to permit condensate drainage. Insulate vent pipe exposed to cold air or routed
through unheated areas. Insulate vent pipe runs longer than 10 ft. (3m). Insulation should be a minimum of ½ in. (12mm)
thick foil faced fiberglass, 1 ½ lb density. Maintain 6in. (152mm) clearance between vent pipe and combustible materials.
An approved Breidert Type L, Field Starkap or equivalent vent cap must be provided. Vent cap inlet diameter must be
same as the required vent pipe diameter. The vent terminal must be at least 12 in. (305mm) from the exterior wall that it
passes through to prevent degradation of building material by flue gases. The vent terminal must be located at least 1 ft.
(305mm) above grade, or in snow areas, at least 3 ft. (1m) above snow line to prevent blockage. Additionally, the vent
terminal must be installed with a minimum horizontal clearance of 4 ft. (1.2m) from electric meters, gas meters, regulators
or relief equipment.
Through the wall vents shall not terminate over public walkways, or over an area where condensate or vapor could create a
nuisance or hazard. Provide Vent termination clearances to building or structure features as follows:
Structure
Door, Window or gravity inlet
Forced air inlet within 10 ft. (3m)
Adjoining building or parapet
Adjacent public walkways
Minimum Clearance
4 ft. (1.2 m) below
4 ft. (1.2 m) horizontally
1 ft. (305 mm) above
3 ft. (.91 m) above
6 ft. (1.8 m)
7 ft. (2.1 m) above grade
EACH APPLIANCE MUST HAVE IT’S OWN INDIVIDUAL VENT PIPE AND TERMINAL. Do not connect vent system
from horizontally vented units to other vent systems or a chimney.
7
Figure 4
Horizontal Venting – Category III
5 ft. (1.52m) Min.
50 ft. (15.25 m) Max.
Equivalent Length
1ft. (305mm) Min.
Approved
Vent Terminal
3 ft. (.91m) Min.
above highest snowfall
2” (51mm) clearance
Thimble with
Fiberglass insulation (2”)
Condensate Drain
With trap – if required
By local codes
Heating Appliance
Separated Combustion Systems
HM duct furnace modules may be applied to appliances for operation in separated combustion systems. The module must be
mounted with the burner section in a reasonably airtight vestibule compartment, as these systems provide combustion air from
outside the heated space and vent the products of combustion outdoors. No air openings are to be provided in the vestibule
access door or panel and sealing grommets or gaskets should be provided for gas and electrical entry points into the vestibule
to provide a reasonably airtight seal.
1.) A suitable airtight gasket on the vestibule door or access panel.
2.) An observation window in the door to permit observation of ignition and main burner flame during operation and
servicing.
3.) A door or panel interlock switch to insure that door or panel is closed or in place during operation.
4.) Openings into the vestibule space for attachment of inlet air supply pipe and vent pipe, sized for the Btuh (W) input
rating.
5.) Approved vent terminals on both the supply air inlet and flue gas exhaust. NOTE: The inlet and outlet terminals
must be located in the same pressure zone to provide for safe appliance operation.
6.) Instructions covering installation and operation for the separated combustion system must be included in the appliance
manufacturer’s Installation and Operation Manual.
Proper installation of air inlet and flue gas exhaust piping are essential to proper operation of the appliance. Inlet air pipe must
be same size as vent pipe based on input ratings. See Figures 5 and 6 for recommended installation.
8
Figure 5
Separated Combustion -Vertical Venting
6 ft. (1.8m) Min.
to Wall or Adjoining
Building
Exhaust Vent
Approved Vent Caps
Combustion Air Inlet
2.5 ft. (0.75m)
Min.
12 in. (0.3m) Min.
18 in. (0.46m) Min. * (See Note)
Exhaust
Tee with Drip Leg and
Cleanout Cap
18 in. (0.46m) Min.
Heating Appliance
* Provide sufficient height to
exceed expected snow depth
Figure 6
Separated Combustion-Horizontal Venting
5 ft. (1.5m) Min.
25 ft. (15.2m) Max.
Equivalent Length
Building Overhang
Pitch pipes down ¼ in./ ft. (21mm / m)
Toward terminal caps to allow for
Condensate drainage
3 ft. (0.9m) Min.
12 in. (0.3m)
6ft. (1.8m)
Min.
24 in.
(0.6m)
9
3 ft. (0.9m) Min.
Above Grade
Size by expected
Snow depth
Adjacent
Building
Gas Piping
1. All gas piping shall conform with local codes and ordinances, or in the absences of local codes with the
National Fuel Gas Code or ANSI Z223.1. In Canada, installation must be in accordance with CAN/CGAB149.1 for Natural gas and B149.2 for Propane Gas.
2. A manual gas shut-off valve must be installed immediately adjacent to the point where the gas supply enters
the cabinet. The appliance must be isolated for the gas supply system be closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½
psi. Always use clean scale free pipe and malleable iron fittings, remove all cutting and threading debris prior
to connecting pipes. Firmly support the gas piping so that it cannot be dislodged from its installed position.
3. Gas piping must be sized for the total BTU input of the appliance. Refer to the unit rating plate for total input.
4. Regulators used must be sized for the total BTU input of the unit.
5. For the unit to operate properly, the inlet gas pressure must be maintained at 5.0” wc for Natural gas and
11.0” wc for propane. Maximum inlet pressure must not exceed 13.0” wc to prevent damage to the gas valve.
6. A 1/8” NPT tap is provided on the of the gas valve to the heater. A fitting suitable of connection to the
pressure gauge capable of measuring gas pressure should be connected to each heater. Check pressures
when with all the units are operating at the same time.
7. A drip leg shall be provided at any point in the line of pipe where condensate and sediment could collect.
Operating and Safety instruction
1. When operating this unit for the first time, it is important to leak test all gas piping and fix any leaks before
turning the unit on.
2. Do not attempt to operate unit, if there is indication that any part or control has been under water. Any control
or component that has been under water must be replaced prior to start up.
Start-up
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Turn thermostat or temperature controller to the lowest setting
Turn off gas supply at the manual shut-off valve
Turn off electrical power at the disconnect switch
Turn gas valve to off position at the control Knob.
Install a manometer or a gauge in the manifold tapped fitting.
Turn the gas valve control knob to On position
Turn gas supply to on position.
Turn electrical power on
Set thermostat to call for heat at the highest setting
LED light at the ignition will light
Induced draft blower will run for 30 second pre-purge period
At the end of the pre-purge period the spark igniter and the gas valve will be energized.
Burners should ignite.
If the unit fails to ignite, see trouble shooting guide inside this instructions,
10
Manifold Pressure Adjustment
•
The manifold pressure for high fire second stage should be at 3.5”wc, if it needs adjustment adjust the
HI Regulator on the two stage gas valve. (See Figure A).
•
The manifold pressure for Low Fire First Stage should be set at 1.2”wc, if it needs adjustment adjust the
LO Regulator on the two stage gas valve. (See Figure A).
Hi
Pressure
Adjustment
LOW
Pressure
Adjustment
Inlet Gas
Pressure
Tap
OFF/ON
turn Knob
Figure A – Honeywell two Stage Gas Valve
Maintenance
It is recommended that an annual inspection of the heater by a qualified service personal. The condition of the
burners, heat exchanger, induced draft blower, venting system and wirings. Check for any signs of deterioration, vent
blockage, any signs of flame rollout or water damage. Any sign of damaged or deteriorated parts should be replaced
before the unit is put back into service.
1.
2.
3.
4.
5.
Turn off all electrical power before inspection and servicing
Check Heat Exchanger for Cracks and blockage.
Check and clean burners and carryover from dirt, rust and blockage by wasp nests.
Check venting system for blockage by animals and wasps.
Check the piping for any possible leaks.
11
Utec 1016-xxx Direct Spark Ignition Control
Sequence of Operation
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Thermostat closes on call for heat providing 24 VAC to Ignition Control
Draft Inducer is energized (@ line voltage)
Air Switch closes initiating 30 second pre-purge.
At end of pre-purge period, Spark and Gas Valve are energized for up to a 5 second ignition trial.
Burners ignite and carryover.
Flame is detected by flame sensor, and control operates in steady state heating condition.
Unit continues in operation until the thermostat is satisfied.
Thermostat opens interrupting power to control and shutting off unit.
If ignition is not achieved within 5 seconds, the gas valve is shut off; the inducer keeps running for an interpurge period. Additional ignition trials follow the specified sequence. If all trials (3) for ignition have
occurred without proper ignition and flame detection, the control locks out.
Control may be brought out of lockout by cycling the thermostat or power off for a minimum of 5 seconds.
If ignition is not achieved within 5 seconds, the gas valve is shut off, and the inducer keeps running for an
inter-purge period. Additional ignition trials follow the specified sequence. If all trials (3) for ignition have
occurred without proper ignition and flame detection, the control locks out. (To restart refer to Item 10)
If flame is lost once it has been established, the control will shut off the gas supply within 0.8 second and
enter the inter-purge period. Control will initiate up to 3 additional trials per normal operation sequence. (To
restart refer to Item 10)
If flame sensor indicates presence of flame during purge period, when no flame should be present, the
inducer will remain energized but the gas valve off until the cause of the “false flame is removed.
If the air pressure switch is closed when the inducer is energized, or does not close after the inducer is
energized, the control will wait one minute for the sir switch to open or close and then lock out. (To restart
refer to Item 10)
If the control detects power to the gas valve when it should be off, or not powered when it should be on,
the control will go into lockout with all outputs off. (To restart refer to 10)
NOTE: Refer to control “ Flash Code Key” if control is provided with LED indicator light.
LED Flash Code Key
On – Steady
1 Flash
2 Flashes
3 Flashes
4 Flashes
5 Flashes
Control operation normal
Open Pressure switch, limit switch or flame rollout switch
Pressure switch stuck closed
Ignition / flame sense failure
Repeated flame losses
Internal control fault
12
Trouble shooting guide for UTEC 1016-xxx Ignition Board
LED Code System
Description
Actions
Steady On Normal
LED is Lit
24VAC is applied to the control
LED off
LED is OFF
1.) Check 120V is supplied to unit and
transformer
Lockout
2.) Check to see if 24V is coming out of
secondary side of transformer, if not change
transformer
1 Flash
Lockout
Open Pressure switch with induced
draft blower energized
1.) Check pressure hose connection between
the draft inducer and pressure switch.
2.) Check rollout switch manual reset to see if
tripped
3.) Check for open high limit
4.) Replace pressure switch
2 Flashes Lockout
Pressure switch closed when induced 1.) Check wiring between PS1 & PS2 on the
draft blower is off.
ignition controls for proper connection
2.) Check pressure switch contacts operations
3.) If pressure switch are closed shut replace
pressure switch.
3 Flashes Lockout
Ignition Lockout from too many trials
1.) Verify gas supply available
2.) Verify the Gas valve is working properly
and manifold pressure is adequate
3.) Check the spark igniter is cracked or dirty
4.) Check to see flame sensor wiring is good
5.) Check to see if the flame sensor is
grounded to the panels
4 Flashes Lockout
Ignition Lockout form to many flame
losses within a single call for heat
1.) Check Pressure switch hose for leaks or
poor connection
2.) Check pressure switch hose for
condensate in line
3.) Check pressure tap in the combustion
blower for dirt blockage
3.) Check the induced draft blower
5 Flashes Lockout
Control hardware fault detected
1.) Change ignition Control board.
13
Sequence of Operation for 1171-63 Utec two-stage board
When the control is in stand by mode the diagnostic red LED will be flashing a heartbeat and is continually monitoring
the thermostat input and safety circuit.
Call for heat:
1- On a call for first stage heat “W1” and “R” closes allowing 24vac to flow to W1 circuit. The control board than
checks to see if the pressure switches are open. If either pressure switch is closed, the control flashes “3” on
the LED and waits indefinitely for it to open. When the pressure switch is sensed as open, the control begins
pressure switch proving period.
2- The Induced Draft blower is energized on High speed and control waits for the pressure switch to close.
3- When the pressure switch closes, a 30 second pre-purge period begins.
nd
4- At the end of the pre-purge period, the spark igniter is energized and then the 2 stage gas valve high fire is
energized.
5- Once the flame is established and detected by the flame sensor, the spark igniter is de-energized and all the
burners should be light.
6- The unit should stay on second stage fire for 120 seconds warm up period regardless what the thermostat is
call for.
7- After this warm up period, the unit will re-act to what thermostat is call for. If the thermostat is calling for first
stage low fire stage, than high stage on the gas valve and on inducer is de-energized and low stage on valve
and inducer energized.
8- When the thermostat is satisfied the gas valve is immediately de-energized and a 30 second post purge period
starts.
LED Faults and operation failures:
Heartbeat
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
9 Flashes
All conditions are normal
Pressure Switch open with inducer on
Pressure Switch closed with inducer off
Lockout from too many failed ignition tries
Lockout from too many flame losses
High temperature switch open
Rollout Switch open
Flame present with gas off
Exceeded max limit trips in one call for heat (5)
1. If the flame is lost during a call for heat the control de-energizes the gas valve and counts the flame loss. If the
burner fails to light or prove flame a total of three times the control will go into a one hour Lockout period.
2. At any time the high temperature limit switch opens the control will run the inducer on high speed, de-energize
the gas valve and Flash “6” on the LED. When the high limit switch closes, the control will restart the ignition
sequence again.
3. If the flame is sensed for longer than 2.0 seconds during when the gas valve should be closed, the control will
enter lockout. The control will turn on the inducer blower, while the flame is present.
4. If the rollout switch opens during normal operation, the control will run the inducer on high speed for the postpurge period, immediately de-energizes the gas valve and flash “7” on the LED.
14
Trouble shooting guide of Utec 1171-63 Two stage board
System
LED Code Mode
Description of
Symptom
Heartbeat
System is functioning
properly
2 Flash
Actions
None
Inducer on, Low pressure switch is open 1- Failed combustion Blower
No gas
2- Check pressure switch hose connection and cracks in the hose
3- Check for blockage in pressure switch hose
4- Check for blockage in the inducer barb fitting
5- Check for condensate accumulation in the pressure switch and hose
6- Replace the pressure switch.
3 Flash
No Flame
Pressure switch In closed
position at start
4 Flash
Lockout
Failed to light and or
1. Verify gas supply available and manifold pressure is correct
carryover, Loss of flame or 2- Verify the gas valve is in the ON position
flame signal during ignition.
3- Verify that a spark in present, if not check igniter for debris between the
electrodes, cracked ceramic and check ignition wire for cracks.
1- Check wiring to the pressure switch
2- Check pressure switch contact for closed contact using an ohm meter
3- Replace the pressure switch.
4- Check to see if the sensor ceramic is cracked or if the electrode wire is
coded with dirt or oils.
5- Check to see if the senor wire is connected properly and not grounded, do
to wire abrasions.
6- Check for air leaks
7- Check for Re-circulation of flue product
8- If all conditions are satisfactory, change the ignition control board.
5 Flash
Lockout
Burners light than drop off
resulting in too many flame
losses
1- Check to see if the sensor ceramic is cracked or if the electrode wire is
coded with dirt or oils.
2- Check to see if the senor wire is connected properly and not grounded, do
to wire abrasions.
3- Check for Re-circulation of flue product
4- Check to see if the flame is floating away from the senor
5- Check to make sure the pressure switch is not dropping out, do to loses of
pressure.
6 Flash
No Flame
Inducer is running on high 1- Check rise and airflow over the heat exchanger
speed, burners ore off. High
limit is open
2- If high limit does not reset, change Limit.
7 Flash
No Flame
Rollout switch has tripped
open
1- Check for any blockage in the flue pipe
2- Check for leakage inside the burner compartment
3- Reset the Rollout switch and observe the flame for any sign of rolling out.
8 Flash
Lockout
Flame is present without any 1- Verify that there is no voltage to the gas valve
call for heat
2- Check line pressure to make it's not higher that allowed by the gas
manufacturer
3- If valve is not energized, check for gas flow. If gas in flowing replace the
gas valve and verify line and manifold pressures.
15
MD - Sequence of Operation –Full Modulation
UT 1016-427 Direct Ignition Control, TR1 Timer and SC30 Modulating Control
16. Thermostat closes on call for heat.
17. 24 VAC to is supplied to Ignition Control terminal “W” through the thermostat.
18. The ignition control will verify the pressure switch is open and limits are in closed positions before energizing the
combustion blower.
19. Draft Inducer is than energized at high speed.
20. The pressure switch closes, and a 30 second pre-purge period begins.
21. At end of pre-purge period, the spark igniter is energized and the Gas Valve is powered at high fire for a 5-second
ignition trial.
22. At the end of the Ignition trial period, TR1 control is powered (SR LED Lit) and begins a 90 second warm-up period
while maintaining the combustion blower at high speed (FR LED lit). The SC30 will than power the modulating valve at
high fire for the duration of the warm-up period.
23. Burners ignite and cross over, once Flame is detected by flame sensor, the spark igniter is shut-off, gas valve and
combustion blower stay energized.
24. When the warm–up period expires, TR1 defaults the gas valve to low fire and the combustion blower to low speed and
returns control of the operating mode to the building temperature controller. The SR LED turns off and the MR LED is
lit.
25. If the building controller is providing an analog signal between 1.0 and 5.3 VDC to the SC30 control, the system will
continue to operate at low fire and low speed combustion blower. The modulating valve will be powered proportional
to the input voltage signal from the controller, and will open or close changing the gas manifold pressure. Manifold
pressure will vary from .40 to 1.2” w.c. .
nd
26. If the signal increases above 5.3 VDC, the combustion blower switches to high speed (FR LED lit) and high fire 2
stage gas valves is energized (CR LED lit). The manifold pressure will vary from 1.4 to 3.5”wc.
27. Operation will continue in High fire mode until the signal from the building management controller drops to below
nd
4.7VDC. At this point the SC30 de-energizes the 2 stage gas valve and the combustion blower switches to low
speed.
28. When the building thermostat is satisfied and the demand for heat ends, the gas valve is de-energized immediately the
combustion blower is energized on high speed for 30-second post-purge period.
29. The Ignition control is capable of three retrials for ignitions if the above sequence is interrupted at any point.
Operational failures during a call for heat result in “lockout” of the ignition control. The control will reset itself one hour after a
lockout occurs and initiate a new trial for ignition sequence. The control may be also be reset manually by cycling the
thermostat or power off for a minimum of 5 seconds.
30. If air pressure switch does not close after the inducer is energized or if limit or rollout switch (es) are open, the control
will wait one minute for the switch to close and then lock out. (1 Flash)
31. If air pressure switch is closed when the inducer is energized, the control will wait one minute for the switch to open
and then close or lock out will occur. (2 Flashes)
32. If flame sensor indicates presence of flame during purge period, when no flame should be present, the inducer will
remain energized but the gas valve off until the cause of the “false flame” is removed. (5 flashes)
33. If ignition is not achieved within 5 seconds, the gas valve is shut off; the inducer keeps running for an inter-purge
period of 60 seconds. Additional ignition trials follow the specified sequence. If all trials (3) for ignition have occurred
without proper ignition and flame detection, the control will lockout. (3 Flashes)
34. If flame is lost once it has been established, the control will shut off the gas supply within 0.8 second and enter the
inter-purge period. Control will initiate up to 3 ignition trials per normal operation sequence. (4 Flashes)
35. If the control detects power to the gas valve when it should be off, or not powered when it should be on, the control will
go into lockout with all outputs off. (5 flashes)
LED Flash Code Key (UT1016-400 Series)
On – Steady
1 Flash
2 Flashes
3 Flashes
4 Flashes
5 Flashes
Control operation normal
Open Pressure switch, limit switch or flame rollout switch
Pressure switch stuck closed
Ignition / flame sense failure
Repeated flame losses
Internal control fault
16
Table 1 - HMA, HMB Series Ratings
Input
Rate
Model
No.
Tube Depth
Min. Max.
Min. Duct
Opening
Min.
Depth
Min. Duct Min. Clearances to
duct from tube.
Area
Height /
Width
Top Bottom
2
Btuh
in.
in.
in.
in.
ft.
W
mm
mm
mm
mm
m2
Rear
in.
in.
in.
mm
mm
mm
Air Flow @ Min.
Output Temp Rise Duct Opening
Btuh
W
Min. Max. Min.
o
o
o
o
F
C
F
C
Max.
cfm
cfm
m3/s
m3/s
HMA Series - Cross flow-Hoizontal or Vertical
HMA-400
HMA350
HMA350
HMA300
HMA250
HMA250
HMA200
HMA150
400,000
31
9.9
320,000
3292
14815
117,228
787
0.92
93782
1.55
6.99
350,000
31
9.9
280,000
2881
12963
102,575
787
0.92
82060
1.36
6.12
350,000
27.75
8.86
280,000
2881
12963
102,575
705
0.82
82060
1.36
6.12
300,000
24.5
7.83
240,000
2469
11111
87,921
622
0.73
70337
1.16
5.24
250,000
24.5
7.83
200,000
2058
9259
73,268
622
0.73
58614
0.97
4.37
250,000
21.25
6.79
200,000
2058
9259
73,268
540
0.63
58614
0.97
4.37
200,000
18
5.75
160,000
1646
7407
58,614
457
0.53
46891
0.78
3.5
150,000
18
5.75
120,000
1235
5556
43,961
457
0.53
35168
0.58
2.62
400,000
33.5
18.03
320,000
3292
14815
117,228
851
1.67
93782
1.55
6.99
375,000
33.5
17.45
300,000
3086
13889
109,901
851
1.62
87921
1.46
6.55
2881
12963
42
1067
48
1321
46
1168
1.75
44
2.75
70
2
51
20
11
90
50
HMB Series - Crossflow- Horizontal or Vertical
HMB400
HMB375
350,000
HMB350
HMB-325
HMB-300
HMB-275
HMB-250
HMB-225
HMA200
HMB175
30.25
16.28
102,575
768
1.51
82060
1.36
6.11
325,000
30.25
14.49
260,000
2675
12037
75.5
75.5
77.5
1.75
2.75
2
280,000
20
90
95,248
768
1.35
76198
1.22
5.5
300,000
27
12.94
240,000
2469
11111
87,921
686
1.2
70337
1.16
5.24
275,000
27
12.94
224,000
2305
10370
82,060
686
1.2
65648
1.09
4.89
250,000
23.75
11.38
200,000
2058
9259
73,268
603
1.06
58614
0.97
4.37
225,000
23.75
11.38
180,000
1852
8333
65,941
603
1.06
52753
0.87
3.93
200,000
20.5
9.82
160,000
1646
7407
1918
1918
1969
44
70
51
11
50
58,614
521
0.91
46891
0.78
3.49
175,000
20.5
9.82
140,000
1440
6481
51,287
521
0.91
41,030
0.7
3.14
17
Table 2 – HMG and HMH Series Ratings
Model
No. /
(No.
Tubes)
Input Rate Tube Depth
Btuh
W
Min. Duct
Opening
Duct Area Min. Clearances to duct Output
from tube.
Temp Rise
Air Flow @ Min.
Duct Opening
Min.
Max.
Min.
Max.
in.
o
F
o
F
cfm
cfm
C
o
C
m3/s
m3/s
80
Min.
Max.
Min.
Depth
Width
Min.
Top
Bottom Rear
in.
in.
in.
in.
ft. 2
in.
in.
mm
mm
mm
mm
m
2
Btuh
mm
mm
mm
W
o
1
1
2
320,000
20
HMG Series - Crossflow Horizontal and Vertical
HMG400
(15)
400,000
26
34
31
49
10.55
3704
14815
117,228
635
864
787
1245
0.98
93782
1.75
6.99
HMG375
(15)
375,000
26
34
28
49
9.53
300,000
3472
13889
109,901
1245
0.89
87921
1.64
6.55
HMG350
(14)
350,000
46.25
8.99
280,000
3241
12963
102,575
1175
0.84
82060
1.53
6.11
HMG325
(14)
325,000
46.25
8.99
260,000
3009
12037
1175
0.84
1.42
5.68
HMG300
(12)
300,000
40.75
8.77
2778
11111
87,921
1035
0.81
70337
1.31
5.24
HMG275
(12)
275,000
40.75
8.77
220,000
2546
10185
80,594
1035
0.81
64475
1.2
4.8
HMG250
(10)
250,000
35.25
7.59
200,000
2315
9259
73,268
895
0.7
58614
1.09
4.37
HMG225
(10)
225,000
35.25
7.59
180,000
2083
8333
65,941
895
0.7
52753
0.98
3.93
HMG200
(8)
200,000
29.75
5.78
1852
7407
58,614
756
0.54
46891
0.87
3.49
HMG175
(7)
175,000
27
5.25
140,000
1620
6481
51,287
686
0.49
41030
0.76
3.06
HMG150
(6)
150,000
24.25
4.72
120,000
1389
5556
43,961
616
0.44
35168
0.66
2.62
HMG125
(5)
125,000
21.5
4.18
1157
4630
36,634
546
0.39
29307
0.55
2.18
HMG100
(4)
100,000
18.75
3.65
80,000
926
3704
29,307
476
0.34
23446
0.44
1.75
HMG075
(3)
75,000
16
3.11
60,000
694
2778
21,980
406
0.29
17584
0.33
1.31
95,248
660
26
660
864
34
864
711
28
711
76198
25
1
25
25
1
25
51
2
51
240,000
160,000
100,000
11
20
11
44
80
44
HMH Series - Crossflow Horizontal and Vertical
HMH 240
(8)
240,000
23.25
7.59
1975
8889
70,337
591
0.7
56269
1.4
4.19
HMH210
(7)
210,000
20.25
6.61
168,000
1728
7778
61,545
514
0.61
49236
1.22
3.67
HMH180
(6)
180,000
17.25
5.63
1481
6667
438
0.52
1.05
3.14
HMH150
(5)
150,000
14.25
4.65
120,000
1235
5556
43,961
362
0.43
35168
0.87
2.62
HMH120
(4)
120,000
11.25
3.67
96,000
988
4444
35,168
286
0.34
28135
0.7
2.1
52,753
45
1143
56
1321
47
1194
1.75
2.75
2
192,000
20
90
144,000
44
18
70
51
42202
11
33
Table 3 – HMC, HMD, HME and HMF Ratings
Model
No.
Input
Rate
Tube Depth
Min.
Max.
Min. Duct
Opening
Min.
Depth
Min.
Duct
Area
Min. Clearances to
duct from tube.
Output Temp Rise
Air Flow @ Min.
Duct Opening
BTUH
Height / Width
Top
2
Btuh
in.
in.
in.
in.
ft.
W
mm
mm
mm
mm
m2
300,000
31
8.61
87,921
787
0.8
265,000
28
7.78
77,664
711
0.72
230,000
25
6.94
Bottom Rear
in.
in.
in.
mm
mm
mm
Min. Max.
o
F
o
C
o
Min.
Max.
F
cfm
cfm
C
m3/s
m3/s
240,000
2469
11111
70337
1.16
5.24
212,000
2181
9815
62131
1.03
4.63
184,000
1893
8519
W
o
HMC Series - Parallel Flow
HMC300
HMC265
HMC230
HMC200
67,406
38
40
40
1.5
2.5
2
90
635
0.65
0.89
4.02
200,000
22
6.11
160,000
1646
7407
58,614
559
0.57
46891
0.78
3.49
200,000
28
5.98
160,000
1646
7407
58,614
711
0.56
46891
0.78
3.49
175,000
25
5.34
140,000
1440
6481
635
0.5
41030
0.68
3.06
965
1016
1016
38
64
51
53925
20
11
50
HMD Series - Parallel Flow
HMD200
HMD175
HMD150
HMD125
HMD100
HMD075
28.75
36
30.75
51,287
1.75
2.75
2
20
90
150,000
22
4.7
120,000
1235
5556
43,961
559
0.44
35168
0.58
2.62
125,000
19
4.06
100,000
1029
4630
36,634
483
0.38
29307
0.49
2.18
100,000
16
3.42
80,000
823
3704
29,307
406
0.32
23446
0.39
1.75
75,000
13
2.78
60,000
617
2778
21,980
330
0.26
17584
0.29
1.31
19.5
4.06
1235
5556
730
914
781
44
70
51
11
50
HME Series - Parallel Flow
150,000
HME150
43,961
28
36
30
125,000
HME125
36,634
100,000
HME100
711
914
762
495
0.38
16.75
3.49
425
0.32
14
2.92
356
0.27
19.5
3.45
495
0.32
100,000
16.75
2.97
29,307
425
0.28
29,307
120,000
1.5
2
2
35168
20
90
100,000
29307
38
51
51
80,000
11
50
23446
0.58
2.62
1029
4630
0.49
2.18
823
3704
0.39
1.75
HMF Series - Parallel Flow
120,000
HMF125
HMF100
35,168
80,000
HMF080
23,446
23.5
597
28
711
25.5
648
14
2.48
356
0.23
96,000
1.5
38
2
51
2
51
988
4444
0.47
2.1
80,000
823
3704
23446
0.39
1.75
658
2963
0.31
1.4
28135
64,000
18756
20
11
90
50
Notes
It is recommended that applications using 50% or more outside air must use stainless steel heat exchanger do to possible condensate
19
20
2011-08-24
A
01
02
ANY ELECTRICAL MODIFICATION MADE TO
THE APPARATUS WITHOUT NAGAS INNOVATION
APPROVAL CANCELS THE WARRANTY
!
05
C
E
PB1
N
NOTE :
LEGEND
120 / 1 / 60
A CONDUCTOR MUST BE USED FOR GROUNDING
AND NOT THE STEEL CONDUCT
FOR THIS TYPE OF UNIT
!
D
ATTENTION:
!
03
04
B
L1
MCA : 13A
F1
PB1
PLC1
R4
MOP : 16A
NOTE :
GND
UNIT WIRINGS ARE COPPER ONLY
FOR CONTROL DIAGRAM THE GAGE USED IS 16AWG
CONTROL FUSE
POWER BLOCK
PLC UNIT
HMA 1 RUN PROOF RELAY
06
07
JUMPER
08
START / STOP
UNIT
FIRE ALARM
11
1
09
DRY CONTACT 120 VAC, MAX
(BY OTHERS)
10
GND
F1
BK
WT
BK
15A
2
(DRY CONTACT 120VAC)
BY OTHERS
BK
3
11
12
13
START / STOP
HEATING
RD
6
14
DRY CONTACT 24 VAC, MAX
(BY OTHERS)
15
+
+
RD
Q1/1
M
Q1/2
I1
Q2/1
R4
I2
Q2/2
(01-34-A)
I3
Q3/1
I4
Q3/2
I5
Q4/1
I6
Q4/2
BN
18
RD
7
19
50
HEATING ON
21
(DRY CONTACT)
51
YL
YL
22
23
56
24
BN
HEATING MODULATION SIGNAL (0-10V)
(BY OTHERS)
55
25
BL
BL
27
2
GN
RD
GN
RD
GN
RD
OR
GN
I7
REQUIRES SHIELDED WIRE
TO PREVENT INDUCTION (BY OTHERS)
THE SHIELDED WIRE MUST BE
GROUNDED AT ONE END ONLY
26
WT
N
L+
17
20
PLC1
3
-
BN
16
BK
L1
I8
28
29
30
31
33
R4
WT
BK
81
82
2
3
71
72
2
3
61
62
2
3
L0
C
+
-
W
R
L2
L1
R
W
L2
L1
R
W
L2
L1
R
W
L2
L1
GN
BK
3
RD
WT
2
GN
BK
58
RD
WT
57
GN
56
RD
55
OR
54
GN
53
34
BL
BK
RD/BK
WT
RD
WT/BK
32
(01-21-B)
35
36
37
38
TO BECKET HM-1 (MODULATING)
39
40
41
42
TO BECKET HM-4 ( 1 STAGE)
TO BECKET HM-3 ( 1 STAGE)
TO BECKET HM-2 ( 1 STAGE)
WIRES COLOURS CHART
BLANC /WHITE
=WT
NOIR/BLACK
=BK
ROUGE/RED
=RD
BLEU/BLUE
=BL
VIOLET/PURPLE
=VT
ORANGE/ORANGE =OR
BRUN/BROWN
=BN
VERT/GREEN
=GN
JAUNE/YELLOW
=YL
NO.
DESIGNED BY:
FIELD WIRING
UNIT TERMINAL
REMOTE CONTROL PANEL TERMINAL
REVISIONS
DESCRIPTION
FP
!
FACTORY WIRING
APPROVED BY:
DATE
BY
2121, Rue Nobel
Sainte Julie Québec
J3E 1Z9
DANGER:
ELECTRIC VOLTAGE / ELECTROCUTION RISK
A BAD INSTALLATION CAN CAUSE MATERIEL DAMAGE,
WOUND OR EVEN DEATH.
ONLY QUALIFIED PEOPLE SHOULD MAKE THE INSTALLATION AND MAINTENANCE
PROJECT:
PO 10826 TAG 11071804
MODEL:
TA350SM + 3X TA350S1
UNIT:
1A
TITLE:
WIRING DIAGRAM
Tel : (438) 338-1101 DRAWING:
Fax : (450) 649-8756
DATE :
Folio no. :
01 / 01
31453-16670_PO 10826 TAG 11071804
2011-08-24
FILE. :
31453-16670
2011-08-24
A
01
02
ANY ELECTRICAL MODIFICATION MADE TO
THE APPARATUS WITHOUT NAGAS INNOVATION
APPROVAL CANCELS THE WARRANTY
!
05
C
E
PB1
N
NOTE :
LEGEND
120 / 1 / 60
A CONDUCTOR MUST BE USED FOR GROUNDING
AND NOT THE STEEL CONDUCT
FOR THIS TYPE OF UNIT
!
D
ATTENTION:
!
03
04
B
L1
MCA : 13A
F1
PB1
PLC1
R4
MOP : 16A
NOTE :
GND
UNIT WIRINGS ARE COPPER ONLY
FOR CONTROL DIAGRAM THE GAGE USED IS 16AWG
CONTROL FUSE
POWER BLOCK
PLC UNIT
HMA 1 RUN PROOF RELAY
06
07
JUMPER
08
START / STOP
UNIT
FIRE ALARM
11
1
09
DRY CONTACT 120 VAC, MAX
(BY OTHERS)
10
GND
F1
BK
WT
BK
15A
2
(DRY CONTACT 120VAC)
BY OTHERS
BK
3
11
12
13
START / STOP
HEATING
RD
6
14
DRY CONTACT 24 VAC, MAX
(BY OTHERS)
15
+
+
RD
Q1/1
M
Q1/2
I1
Q2/1
R4
I2
Q2/2
(01-34-A)
I3
Q3/1
I4
Q3/2
I5
Q4/1
I6
Q4/2
BN
18
RD
7
19
50
HEATING ON
21
(DRY CONTACT)
51
YL
YL
22
23
56
24
BN
HEATING MODULATION SIGNAL (0-10V)
(BY OTHERS)
55
25
BL
BL
27
2
GN
RD
GN
RD
GN
RD
OR
GN
I7
REQUIRES SHIELDED WIRE
TO PREVENT INDUCTION (BY OTHERS)
THE SHIELDED WIRE MUST BE
GROUNDED AT ONE END ONLY
26
WT
N
L+
17
20
PLC1
3
-
BN
16
BK
L1
I8
28
29
30
31
33
R4
WT
BK
81
82
2
3
71
72
2
3
61
62
2
3
L0
C
+
-
W
R
L2
L1
R
W
L2
L1
R
W
L2
L1
R
W
L2
L1
GN
BK
3
RD
WT
2
GN
BK
58
RD
WT
57
GN
56
RD
55
OR
54
GN
53
34
BL
BK
RD/BK
WT
RD
WT/BK
32
(01-21-B)
35
36
37
38
TO BECKET HM-1 (MODULATING)
39
40
41
42
TO BECKET HM-4 ( 1 STAGE)
TO BECKET HM-3 ( 1 STAGE)
TO BECKET HM-2 ( 1 STAGE)
WIRES COLOURS CHART
BLANC /WHITE
=WT
NOIR/BLACK
=BK
ROUGE/RED
=RD
BLEU/BLUE
=BL
VIOLET/PURPLE
=VT
ORANGE/ORANGE =OR
BRUN/BROWN
=BN
VERT/GREEN
=GN
JAUNE/YELLOW
=YL
NO.
DESIGNED BY:
FIELD WIRING
UNIT TERMINAL
REMOTE CONTROL PANEL TERMINAL
REVISIONS
DESCRIPTION
FP
!
FACTORY WIRING
APPROVED BY:
DATE
BY
2121, Rue Nobel
Sainte Julie Québec
J3E 1Z9
DANGER:
ELECTRIC VOLTAGE / ELECTROCUTION RISK
A BAD INSTALLATION CAN CAUSE MATERIEL DAMAGE,
WOUND OR EVEN DEATH.
ONLY QUALIFIED PEOPLE SHOULD MAKE THE INSTALLATION AND MAINTENANCE
PROJECT:
PO 10826 TAG 11071805
MODEL:
TA350SM + 3X TA350S1
UNIT:
2A
TITLE:
WIRING DIAGRAM
Tel : (438) 338-1101 DRAWING:
Fax : (450) 649-8756
DATE :
Folio no. :
01 / 01
31454-16670_PO 10826 TAG 11071805
2011-08-24
FILE. :
31454-16670
Multiple unit controller
Heaters configuration
The heating system is made of one modulating heater (SM) with a 4 to 1 turndown ratio coupled
with one or more 1-stage heaters (S1). A single PLC controls all heaters independently with the
modulating heater firing at up to 4 stages and the 1-stage heaters firing at full fire.
When the call for heat increases, the PLC turns ON the modulating heater. If the needed heat
output is higher than the capacity of the heater, one single-stage heater will be turned on and
the modulating heater will be fired at 0% capacity, 50% capacity or 100% capacity. As more heat
is needed (and if more heaters are available in the system) another single-stage heater is turned
ON and the modulating heater is fired at 0%, 50% or 100% capacity.
To prevent unneeded cycling of stages and heaters, a timer is in function between stages up or
down in capacity.
The following schematic shows the number of stages and the total output depending on the
heat available.
Systems with 4 heaters (based on 400MBH heaters)
Air
Stage
Heater A1
(S1)
Heater B1
(S1)
Heater A2
(SM)
Heater B2
(S1)
Input
voltage
(Vdc)
Percentage of
modulating
heater (A2)
Percentage of single-stage heaters
B2
Input
heat
(MBH)
Output
heat
(MBH)
A1
B1
1
1.00
25%
0%
0%
0%
100
80
2
2.00
50%
0%
0%
0%
200
160
3
3.00
75%
0%
0%
0%
300
240
4
4.00
100%
0%
0%
0%
400
320
5
5.00
50%
100%
0%
0%
600
480
6
6.00
100%
100%
0%
0%
800
640
7
7.00
50%
100%
100%
0%
1000
800
8
8.00
100%
100%
100%
0%
1200
960
9
9.00
50%
100%
100%
100%
1400
1120
10
10.00
100%
100%
100%
100%
1600
1280
Systems with 6 heaters (based on 300MBH heaters)
Air
Stage
Heater A1
(S1)
Heater B1
(S1)
Heater A2
(SM)
Heater B2
(S1)
Heater A3
(S1)
Heater B3
(S1)
Input
voltage
(Vdc)
Percentage
of
modulating
heater (A2)
Percentage of single-stage heaters
B3
Input heat
(MBH)
Output
heat (MBH)
A1
A3
B1
B2
1
0.71
25%
0%
0%
0%
0%
0%
75
60
2
1.43
50%
0%
0%
0%
0%
0%
150
120
3
2.14
75%
0%
0%
0%
0%
0%
225
180
4
2.86
100%
0%
0%
0%
0%
0%
300
240
5
3.57
50%
100%
0%
0%
0%
0%
450
360
6
4.29
100%
100%
0%
0%
0%
0%
600
480
7
5
50%
100%
100%
0%
0%
0%
750
600
8
5.71
100%
100%
100%
0%
0%
0%
900
720
9
6.43
50%
100%
100%
100%
0%
0%
1050
840
10
7.14
100%
100%
100%
100%
0%
0%
1200
960
11
7.86
50%
100%
100%
100%
100%
0%
1350
1080
12
8.57
100%
100%
100%
100%
100%
0%
1500
1200
13
9.29
50%
100%
100%
100%
100%
100%
1650
1320
14
10.00
100%
100%
100%
100%
100%
100%
1800
1440
PLC display and run mode
The PLC has a display that shows its status.
To start the program, the PLC has to be in "RUN" mode. To activate the run mode, do the
following:
________________________________________________
Issue Date : 2011-10-06
www.serescodehumidifiers.com
Supersedes : 2011-09-20
Seresco Technologies Inc. has a policy of continuous product and product data improvement and reserves the right to change
design and specifications at any time without prior notification. Only qualified technicians working within their area of
competence should perform the installation and maintenance of equipment referred to in this literature.