CaptiveAire EMS Installation Manual

Energy Management System Control

Installation, Operation, and Maintenance Manual

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RECEIVING AND INSPECTION

Upon receiving unit, check for any interior and exterior damage, and if found, report it

WARNING!!

immediately to the carrier. Also check that all accessory items are accounted for and are damage free.

Installation of this control should only be performed by a qualified professional who has read and understands these instructions and is familiar with proper safety precautions. Improper installation poses serious risk of injury due to electric shock, and other potential hazards. Read this manual thoroughly before installing or servicing this equipment. ALWAYS disconnect power prior to working on module.

. This document is the property of the owner of this equipment and is required for future maintenance. Leave this document with the owner when installation or service is complete.

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TABLE OF CONTENTS

WARRANTY .................................................................................................................................................. 2

INSTALLATION ............................................................................................................................................. 3

Mechanical ................................................................................................................................................ 3

Site Preparation .................................................................................................................................... 3

Assembly .............................................................................................................................................. 3

Utility Cabinet Installation (Typical) ...................................................................................................... 3

Wall Mount Installation (Optional) ........................................................................................................ 3

Duct Sensor Installation ....................................................................................................................... 4

Electrical ................................................................................................................................................... 5

Copper Wire Ampacity ......................................................................................................................... 5

Variable Frequency Drive (VFD) Installation Instructions .................................................................... 6

ACTECH SMV VFD CROSS-REFERENCE TABLE ............................................................................ 7

OPERATION ................................................................................................................................................. 8

Start Up ..................................................................................................................................................... 8

Special Tools Required ........................................................................................................................ 8

Start Up Procedure ............................................................................................................................... 8

Water Wash Option .............................................................................................................................. 9

Loss of Load Relay Option ................................................................................................................... 9

Component Description .......................................................................................................................... 10

Variable Frequency Drive ................................................................................................................... 10

Temperature Control .......................................................................................................................... 11

Temperature Sensor........................................................................................................................... 12

100% Override Timer ......................................................................................................................... 13

Water Wash Timers (Optional) ........................................................................................................... 13

Troubleshooting .................................................................................................................................. 14

MAINTENANCE .......................................................................................................................................... 15

General Maintenance ............................................................................................................................. 15

Every Month ............................................................................................................................................ 15

Enclosure Fan Filter Inspection (Wall Mounted Enclosures Only). .................................................... 15

Start-Up and Maintenance Documentation ............................................................................................ 16

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WARRANTY

This equipment is warranted to be free from defects in materials and workmanship, under normal use and service, for a period of 12 months from date of shipment. This warranty shall not apply if:

1. The equipment is not installed by a qualified installer per the MANUFACTURER’S installation instructions shipped with the product,

2. The equipment is not installed in accordance with federal, state and local codes and regulations,

3. The equipment is misused or neglected,

4. The equipment is not operated within its published capacity,

5. The invoice is not paid within the terms of the sales agreement.

The MANUFACTURER shall not be liable for incidental and consequential losses and damages potentially attributable to malfunctioning equipment. Should any part of the equipment prove to be defective in material or workmanship within the 12-month warranty period, upon examination by the MANUFACTURER, such part will be repaired or replaced by MANUFACTURER at no charge. The BUYER shall pay all labor costs incurred in connection with such repair or replacement. Equipment shall not be returned without MANUFACTURER’S prior authorization and all returned equipment shall be shipped by the BUYER, freight prepaid to a destination determined by the MANUFACTURER.

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INSTALLATION

It is imperative that this unit is installed and operated with the designed airflow and electrical supply in accordance with this manual. If there are any questions about any items, please call the service department at 1-866-784-6900 for warranty and technical support issues.

Mechanical

WARNING: DO NOT LIFT CONTROL BY WIRING COMPONENTS

Site Preparation

1. Provide clearance around installation site to safely install equipment into its final position. Supports must adequately support equipment. Refer to manufacturer’s estimated weights.

2. Consider general service and installation space when locating unit.

Assembly

When the energy management system is ordered in a utility cabinet installed on the hood, there is no mechanical assembly required by the installer. If the energy management system is ordered as a wall mount configuration, the enclosure must be secured to a fixed wall near the exhaust hoods.

Utility Cabinet Installation (Typical)

Wall Mount Installation (Optional)

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Duct Sensor Installation

When a modulating energy management system is ordered, the system consists of one duct sensor per fan. If there are multiple risers connected to a single fan, the sensor must be installed where the ducts come together before the fan unless an EMS with “Multi-Stat” is used. In that case, one sensor is installed in every riser. These sensors are shipped factory installed in factory assembled hood risers if there is one riser per fan. If the risers are field cut or the sensor needs to be installed at the junction of the ducts, the sensor and other components are shipped loose for field installation as shown below. A hole must be cut in the grease duct and the quick seal and sensor must be assembled as shown. The sensor has a built in junction box that wires can be run through conduit and attached to.

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Electrical

WARNING!!

IMPORTANT!!

Before connecting power to the control, read and understand the entire section of this document. As-built wiring diagrams are furnished with each control by the factory, and are attached either to the door of the unit or provided with a paperwork packet.

Electrical wiring and connections should be done in accordance with local ordinances and the National Electric Code, ANSI/NFPA70. Be sure the voltage and phase of the power supply and the wire amperage capacity is in accordance with the unit nameplate.

Disconnect power before installing or servicing control. High voltage electrical input is needed for this equipment. This work should be performed by a qualified electrician.

1. Always disconnect power before working on or near this equipment. Lock and tag the disconnect switch or breaker to prevent accidental power up.

2. There are multiple electrical connections required for this control. 120VAC should be wired to terminals H1 and N1. Input power to the variable frequency drives should be wired to “L” series terminals. Drive input power should match the nameplate on the drive. Output power from the variable frequency drives is always 3 phase and should match the voltage requirements of the fan motors. The output power from the drive should be connected to “T” series terminals.

3. Make certain that the power source is compatible with the requirements of your equipment. The energy management system wiring schematic identifies the proper phase and voltage of the equipment.

4. Before connecting control to power source, verify power line wiring is de-energized.

5. Secure the power cable to prevent contact with sharp objects.

6. Do not kink power cable and never allow the cable to come in contact with oil, grease, hot surfaces or chemicals.

7. If the control is a wall-mount system, the duct mounted temperature sensor will need to be wired in. The temperature sensor should be wired to terminal blocks as indicated on the wiring schematic. The hood lights wiring will also need to be wired to terminals “B” and “W”. The fire system micro-switch will need to be wired to terminals “C1”, “AR1”, and “TR1”. C1 is the common, AR1 is the armed state, and TR1 is the triggered state. Verify connections on wiring schematic.

8. Multi-strand thermostat wire must be used to wire the duct temperature sensors back to the main panel.

9. Before powering up the system, make sure that the interior of the control is free of loose debris or shipping materials.

10. If motors are spinning in the incorrect direction, switch any two wires on the output of the variable frequency drive.

11. If any of the original wire supplied with the system must be replaced, it must be replaced with type THHN wire or equivalent.

Copper Wire Ampacity

Wire Size AWG Maximum Amps

14 15 12 20 10 30

8 50 6 65 4 85

When exhaust duct connections are located and cut in the field, duct temperature probes are shipped loose in the electrical package enclosure. These must be installed in the duct immediately above the hood for proper system operation.

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