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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 THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK 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) THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK A-2 Issue Date : 2011-10-06 Issue Date : 2011-10-06 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 THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK 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 THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK 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 Page 1 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 Page 4 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 G - NV Series CommandCenter Operation Page 5 10/6/2011 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 G - NV Series CommandCenter Operation [Optional] [Optional] [Optional] Page 6 10/6/2011 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 G - NV Series CommandCenter Operation Page 7 10/6/2011 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. G - NV Series CommandCenter Operation Page 8 10/6/2011 5.6.1. 5.6.2. Tested Commissioned G - NV Series CommandCenter Operation Page 9 10/6/2011 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 G - NV Series CommandCenter Operation Page 10 10/6/2011 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. G - NV Series CommandCenter Operation Page 11 10/6/2011 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. G - NV Series CommandCenter Operation Page 12 10/6/2011 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. G - NV Series CommandCenter Operation Page 13 10/6/2011 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. G - NV Series CommandCenter Operation Page 14 10/6/2011 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. G - NV Series CommandCenter Operation Page 15 10/6/2011 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). G - NV Series CommandCenter Operation Page 16 10/6/2011 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. G - NV Series CommandCenter Operation Page 17 10/6/2011 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. G - NV Series CommandCenter Operation Page 18 10/6/2011 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. G - NV Series CommandCenter Operation Page 19 10/6/2011 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. G - NV Series CommandCenter Operation Page 20 10/6/2011 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 efciency 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 Modications / 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 . . . . . . . . . . . . . . . . . . . . . L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 1/39 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 L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 2/39 22 23 23 24 Assembly instructions ECblue 9.4 9.5 9.6 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manufacturer reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 3/39 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 specic 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 qualications 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 modications. 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. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 4/39 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 specied 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 notications 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 modications 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. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 5/39 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 signicant 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 specications (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 qualications 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. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 6/39 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 specications 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 specications 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. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 7/39 Assembly instructions ECblue • Safety information Maintenance work may only be carried out by suitably qualied 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 Modications / interventions in the device Attention! For reasons of safety, no unauthorized interventions or modications may be made on the device. All planned modications must be authorized by the manufacturer in writing. Use only genuine spare parts / genuine wearing parts / genuine accessories from ZiehlAbegg.These parts were specically 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. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 8/39 Assembly instructions ECblue • 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 specic 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 specications are to be considered! 3.2 Functional description ECblue stands for EC fans with maximum efciency. Highly efcient, 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 _._ _ Part.-No. 00295296-GB 9/39 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 specications 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 specications 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 sufcient 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. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 10/39 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. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 11/39 Assembly instructions ECblue • • 4.2 Mounting Tighten the fastenings with the specied 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. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 12/39 Assembly instructions ECblue 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 sufcient 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. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 13/39 Assembly instructions ECblue 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 sufcient 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 16/39 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 conrmed 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. Roong 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 17/39 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 Part.-No. 00295296-GB 18/39 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. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 19/39 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 sufceintly retightened innitely. • Remants from installation und foreign object may not remain on the inside! L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 20/39 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 sufcient 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 specications (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 specications (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. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 21/39 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 dened 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. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 22/39 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 L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 23/39 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! L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 24/39 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 retrotted 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 specied in the documentation for the auxiliary module. L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 25/39 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 specications on the type plate? L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 26/39 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 27/39 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 L-BAL-F036-GB 1007 Index 004 Part.-No. 00295296-GB 28/39 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 Part.-No. 00295296-GB 29/39 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 specied 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 specied 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 Specication 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 specied 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 dened 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 classied 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 33/39 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 dened 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 specic technical documentation in accordance with Appendix VII B has been written and is available in its entirety. The person authorised for compiling the specic technical documentation is: Dr. O. Sadi, address see above. The specic documentation will be transmitted to the ofcial authorities on justied 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.