CaptiveAire EMSplus Installation Manual

Installation, Operation, and Maintenance Manual

Save these instructions. 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.

RECEIVING AND INSPECTION Upon receiving unit, check for any interior and exterior damage, and if found, report it immediately to the carrier. Also check that all accessory items are accounted for and are damage free.

WARNING!! 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.

A0017802

April 2011 Rev. 2

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

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

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

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

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

Functionality ............................................................................................................................................ 10

Individual Fan Control ........................................................................................................................ 10

Preparation Time Mode ...................................................................................................................... 11

Hood Lights ........................................................................................................................................ 11

Self-Cleaning function (Optional) ....................................................................................................... 11

Fan Proving Interlock (i.e. Loss of Load Interlock/Airflow Fault Interlock) ......................................... 12

2nd Stage Cooling Interlock for RTU or Dedicated Make-Up Air with DX Coil.................................... 13

BACNET DDC Controls (Optional) ..................................................................................................... 13

Configuration........................................................................................................................................... 13

Security ............................................................................................................................................... 13

Setup Options ..................................................................................................................................... 14

Scheduling .......................................................................................................................................... 24

Status and Diagnostics ........................................................................................................................... 27

Alarms ................................................................................................................................................ 27

Status Page ........................................................................................................................................ 27

Fan Status Page ................................................................................................................................. 27

Drive Diagnostics ................................................................................................................................ 28

Temperature Sensors Reading Page ................................................................................................. 28

CORE ................................................................................................................................................. 29

Component Description ............................................................................................................................... 30

Variable Frequency Drive ................................................................................................................... 30

Variable Frequency Drive Parameters ............................................................................................... 30

Temperature Sensor........................................................................................................................... 31

Room Temperature Sensor ................................................................................................................ 31

Programmable Logic Controller (PLC) ............................................................................................... 31

Touch Screen Interface ...................................................................................................................... 31

ANNEX A: BACNET Objects......................................................................................................................... 1

Troubleshooting ............................................................................................................................................ 1

MAINTENANCE ............................................................................................................................................ 2

General Maintenance ............................................................................................................................... 2

Self-Cleaning ............................................................................................................................................ 2

Start-Up and Maintenance Documentation .............................................................................................. 3

A0017802

April 2011 Rev. 2

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.

A0017802

April 2011 Rev. 2

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)

A0017802

April 2011 Rev. 2

Duct Sensor Installation

When an EMSplus is ordered, the system consists of one duct sensor per riser. These sensors are shipped factory installed in factory assembled hood risers. If the risers are field cut, 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 below. A 3-wire RTD cable, run in conduit, should be used to wire the sensors back to the controller.

A0017802

April 2011 Rev. 2

Copper Wire Ampacity

Wire Size AWG

Maximum Amps

30 8 50 6 65 4 85

Electrical

WARNING!! 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.

IMPORTANT!! 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.

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.

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 panel is wall-mounted, the duct mounted temperature sensors will need to be wired in the field. 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 (brown, brown, black) must be used to wire the Duct Temperature sensors and the room temperature sensor 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 any of the original wire supplied with the system must be replaced, it must be replaced with type THHN wire or equivalent.

A0017802

April 2011 Rev. 2

Variable Frequency Drive (VFD) Installation Instructions

Input AC Power

1. Circuit breakers feeding the VFDs are recommended to be thermal-magnetic and fast acting. They should be sized 1.5 times the input amperage of the drive. Refer to the table below.

2. Each VFD should be fed by its own breaker. If multiple VFDs are to be combined on the same breaker, each drive should have its own protection measure (fuses or miniature circuit breaker) downstream from the breaker.

3. Input AC line wires should be run in conduit from the breaker panel to the drives. AC input power to multiple VFDs can be run in a single conduit if needed.

4. The VFD should be grounded on the terminal marked PE.

STOP! DO NOT connect incoming AC power to output terminals T1, T2, T3. Severe damage to the drive will result.

Output Power

1. Motor wires from each VFD to its respective motor MUST be run in a separate steel conduit away from control wiring and incoming AC power wiring to avoid noise and crosstalk between drives.

2. If the distance between the VFD and the motor exceeds 250 FT, an output reactor should be used between the VFD and the motor. The output reactor should be sized accordingly.

3. If the distance between the VFD and the motor is between 500 and 1000 FT, a dV/dT filter should be used.

4. No contactor should be installed between the drive and the motor. Operating such a device while the drive is running can potentially cause damage to the power components of the drive.

5. When a disconnect switch is installed between the drive and motor, it should only be operated when the drive is in a STOP state.

Programming

1. Most VFD parameters are preprogrammed at the factory when proper information about the fan motors is provided. However the 2 parameters below should be verified in the field during startup.

2. The Drive should be programmed for the proper motor voltage. Refer to parameter P107 in the “Component Description - Variable Frequency Drive” chapter below. P107 is set to 0 (Low) if motor voltage is 120 VAC, 208 VAC or 400 VAC. P107 is set to 1 (High)

if motor voltage is 230 VAC, 480 VAC or 575 VAC.

3. The Drive should be programmed for the proper motor overload value. Refer to parameter P108 in the “Component Description - Variable Frequency Drive” chapter below. P108 is calculated as Motor FLA x 100 / Drive Output Rating (available in table below).

A0017802

April 2011 Rev. 2

ACTECH SMV VFD CROSS-REFERENCE TABLE

M/N

Volts

1Ø

input

3Ø

input

Input

Amps

1Ø

120VAC

Input

Amps

1Ø

240VAC

Output

Amps

KVA

Breaker

1Ø

120VAC

Breaker

1Ø

240VAC

ESV251N01SXB531

120/

240V X

0.33

6.8

3.4

1.7

0.816

ESV371N01SXB531

120/

240V X

0.5

9.2

4.6

2.4

1.104

ESV751N01SXB531

120/

240V X 1 16.6

8.3

4.2

1.992

ESV112N01SXB531

120/

240V X

1.5

10 6 2.4

Input

Amps

1Ø

Input

Amps

3Ø

Breaker

1Ø

Breaker

3Ø

ESV371N02YXB531

240V X X

0.5

5.1

2.9

2.4

1.20

ESV751N02YXB531

240V X X 1 8.8 5 4.2

2.08

ESV112N02YXB531

240V X X

1.5

6.9 6 2.86

ESV152N02YXB531

240V X X 2 13.3

8.1 7 3.36

ESV222N02YXB531

240V X X 3 17.1

10.8

9.6

4.48

ESV402N02TXB531

240V X 5

18.6

16.5

7.72 30

ESV552N02TXB531

240V X

7.5 26

10.80

ESV752N02TXB531

240V X

10 33

13.70

ESV113N02TXB531

240V X

15 48

19.93

ESV153N02TXB531

240V X

20 59

24.50

ESV751N04TXB531

480V X 1

2.5

2.1

2.08 15

ESV112N04TXB531

480V X

1.5 3.6 3 2.99 15

ESV152N04TXB531

480V X 2

4.1

3.5

3.40 15

ESV222N04TXB531

480V X 3

5.4

4.8

4.48 15

ESV402N04TXB531

480V X 5

9.3

8.2

7.72 15

ESV552N04TXB531

480V X

7.5 12.4

10.30

ESV752N04TXB531

480V X

10 15.8

13.12

ESV113N04TXB531

480V X

15 24

19.93

ESV153N04TXB531

480V X

20 31

25.74

ESV183N04TXB531

480V X

25 38

31.56

ESV223N04TXB531

480V X

30 45

37.37

ESV751N06TXB531

600V X 1 2 1.7

2.08 15

ESV152N06TXB531

600V X 2

3.2

2.7

3.32 15

ESV222N06TXB531

600V X 3

4.4

3.9

4.57 15

ESV402N06TXB531

600V X 5

6.8

6.1

7.06 15

ESV552N06TXB531

600V X

7.5 10.2

10.59

ESV752N06TXB531

600V X

10 12.4

12.87

ESV113N06TXB531

600V X

15 19.7

20.45

ESV153N06TXB531

600V X

20 25

25.95

ESV183N06TXB531

600V X

25 31

32.18

ESV223N06TXB531

600V X

30 36

37.37

A0017802

April 2011 Rev. 2

OPERATION

Operation Chart

Prior to starting up or operating the EMSplus, check all fasteners and wires for tightness. The VFDs (variable frequency drives) included in this system have been factory programmed at 60Hz for high speed and 48Hz for low speed. This results in a 20% reduction in airflow when operation is in low speed. The VFDs are used to adjust the speed of 3 phase motors and frequency is directly proportionate to airflow.

Start-Up

Special Tools Required

 AC Voltage Meter  Amperage Meter  Standard Hand Tools

Start Up Procedure

1. Once all power, lights, inputs, outputs and temperature sensor(s) are connected, startup can begin. Before applying power to the EMSplus, verify that breaker CB-01 is turned off. Apply power. Turn CB-01 ON. The Touch Screen Panel will power up and beep. If that is not the case, check all power connections.

2. Verify that the COM indicator Light on top of the Touch Screen Panel is lighted green. If that is not the case, verify that the serial cable going from the back of the panel to the Controller is

properly plugged in. Make sure the Grey connector is labeled “HMI” on the side of the Touch

Screen Panel and “PLC” on the side of the controller. If there is still no communication, cycle

power to the Unit once more by turning CB-01 ON and OFF.

A0017802

April 2011 Rev. 2

Verify that the “PLC

Running Light” is green. If

it is not, the PLC is not running and the configuration of the PLC was not properly completed.

Verify that there are no alarm messages displayed here. If there are, press ACKN to make them disappear after they are resolved. Press MUTE to silence the alarm.

4. Press the Lights icon on the Touch Screen to energize the hood lights. If the lights do not come on, make sure the light bulbs are installed or check the lighting circuit. If the system is configured for multiple light circuits, pressing the Lights icon will take you to the Hood Lights Control Page. From there, press the All Lights icon to energize all light circuits.

5. Press the Fans icon on the Touch Screen to energize the VFD and fan. If the Preparation Mode is enabled, press the Prep OFF button to run in

normal mode.

If there are multiple fans on the job and the Individual Fan Control is selected (factory default), pressing the Fans icon will take you to the Exhaust Fan Control Page. From there, press the All Fans icon to energize all VFDs and Fans. If the Preparation Mode is enabled, press the Prep OFF button to run in normal mode.

The fans take a few seconds to come up to speed. The VFDs should all indicate 48Hz and the Fans indicator light should be green and “turning”. This indicates that the fans are operating on low speed. If the supply fan drive does not power up, the fire system micro-switch might not be in the armed position or might not have been properly connected. A fire system distributor should service the micro-switch or arm the fire system.

A0017802

April 2011 Rev. 2

6. Press the 100% Override button on the Touch Screen interface. The 100% Override button should turn green and all of the VFDs should ramp up to their respective high speed (60Hz factory default for Americas). The fans should stay at this speed for a factory set time of 30 minutes. This time is adjustable as described in the Setup section. After the time interval expires, the drives should return to 48Hz or low speed. The high speed and low speed frequencies are adjustable as described in the Setup section. One can also return the system to normal operation by pushing the 100% Override button again before the timer expires.

7. The % Savings Icon on the Main page provides information on how much Fan Energy is saved by the system when running the fans at lower speed. It is calculated based on the actual Kilowatts measured from each Variable Frequency Drive controlling the fans. However it doesn’t include the additional savings resulting from the lower CFM of Make-up air and HVAC air that require heating or cooling.

8. If the cooking appliances are connected to an Electric gas valve controlled by the EMSplus, the gas valve can be turned ON by pressing the Gas Valve icon for a couple of seconds. The icon will only show if the Gas Valve Present Option is turned ON on the Setup page.

9. Turn on the cooking appliance and allow them to reach idle temperature. If the fans are off, the fans should automatically be energized as the cooking appliance heats up. The low temperature set point should be set to approximately 10 degrees above kitchen room temperature. See the Exhaust Fan Setup section for further details.

The appliances running in idle mode should not make the EMSplus system operate at high speed. The fans should modulate during the cooking process. If the fans go to high speed while the cooking appliances are idling, the high temperature set point should be increased. See the Exhaust Fan Setup section for further details. If the fans never or rarely go to high speed while cooking is taking place, the high temperature set point should be decreased.

10. If the control contains the Self Cleaning option, an additional icon will be displayed on the Main screen. Push the icon to start the wash cycle. Water will be sprayed in the plenum and duct of the hood and surfactant will be injected at a set frequency. The wash cycle will stop when the wash timer expires or when the Wash icon is pressed again. Make sure Hood filters remain in place during the wash cycle.

Functionality

Individual Fan Control

1. This option is enabled by default from the factory. It can be disabled under Setup → Fan Setup.

2. This option makes the exhaust fans behave independently from each other. This means that they can be turned ON/OFF separately. This allows for greater energy savings since exhaust fans covering hoods that are not used can be shut down completely.

3. In systems that include 1 or 2 supply fans, one or several exhaust fans might have to be sped up or forced ON automatically by the system under some conditions in order to maintain the kitchen pressure balance while ensuring the supply fan is still delivering its minimum specified CFM. The system will decide which fan to force ON and at what speed to run it in order to minimize energy waste. Forcing will not occur if the fans are running in Preparation Time mode or in Wash mode since the Supply fans are maintained OFF.

4. In Preparation Time mode, all exhaust fans are also independently controlled. However if one exhaust fan goes out of Preparation Time mode, all other exhaust fans assigned to the same supply fan will also exit the preparation Time mode.

A0017802

April 2011 Rev. 2

5. In some configurations with 3 or more exhaust fans, 2 exhaust fans might need to always run together, for example if those 2 fans are covering the same hood. To achieve this, the Link Exh Fans function under Setup → Fan Setup can be used. More details about this function can be found under the Setup Options section below. If 2 fans are linked, they will always come ON and OFF together, except if one of them is “Forced” On as described in item 3 above.

6. When individual fan control is selected, Supply Dampers should be used if a supply fan is feeding make-up air to more than 1 exhaust fan through Perforated Supply Plenums. The dampers should be installed in the main supply duct above each exhaust fan. This will ensure that make-up air is not supplied to an exhaust fan when it is not operating.

Preparation Time Mode

1. This option is enabled by default from the factory. It can be disabled under Setup → Fan Setup.

2. Preparation Time Mode is available for morning operation when appliances are off or when very light food preparation is performed. Dedicated make-up air will be locked out only allowing the use of transfer air during this mode. Exhaust fan(s) will run at low CFM while maintaining a balanced kitchen pressure.

3. Preparation Time mode can be initiated by different means:

 By pressing the fan icon on the Touch Screen  Through the schedule when Fan Schedule is enabled.  Remotely through the building management system in BMS mode or through BACNET

network if installed

 If the “Room Thermostat” Option is enabled (factory default), when the duct temperature

exceeds Room Temperature Measured + Prep Time Temp Offset (Factory Default: 5 °F).

4. The fans will go back to running in modulation mode if the Prep Off button is pressed on the Main screen, if the 100% Override button is pressed or if the temperature sensors in the duct measures a temperature above the Low Temp set point. Low Temp Set point is defined under Setup Options, items 3. a), b) and c).

5. Note: The speed of the exhaust fan(s) in Preparation Time is calculated automatically and is equal to the speed that will produce the same amount of CFM than the Transfer CFM when the fans are running in full speed in normal operation.

Hood Lights

1. An EMSplus system can have between 1 and 8 light circuits. This allows the load on each circuit to stay below 1400W. It also allows separate control of each light circuit. For example, if the system contains multiple hoods, each hood can have its own light circuits.

2. Circuits for hood light can be controlled manually through the Lights Icon on the Touch Screen. But they will also be automatically turned ON or OFF when the Exhaust fan assigned to that circuit turns ON or OFF. However the manual command on the Touch Screen always takes priority. So if the lights come ON automatically, they can be turned OFF through the Touch Screen. And if they are turned ON through the Touch Screen, they cannot be automatically tuned OFF.

3. If there are multiple hood light circuits, the assignment to exhaust fans can be configured under

Setup → Hood Lights Setup.

Self-Cleaning function (Optional)

1. During the wash cycle, water will be sprayed in the plenum and duct and surfactant will be injected at a set frequency. The wash cycle will stop when the wash timer expires or when the Wash icon is pressed again.

2. The wash timer is factory set to 3 minutes and is adjustable through the Wash Setup Page. The surfactant is injected for 1 second at the start of each minute of Wash. This setting is not adjustable.

April 2011 Rev. 2

A0017802

+ 27 hidden pages