BY JOHNSON CONTROLS
FAN POWERED VAV TERMINALS
INSTALLATION, OPERATION & MAINTENANCE
MODELS CFR, CFRQ, CFL, VFR & VFL
New Release
Form ET130.13-NOM3 (708)
LD13847
FORM ET130.13-NOM3 (708)
TABLE OF CONTENTS
SAFETY CONSIDERATIONS ........................................................................................................................4
INSPECTION .................................................................................................................................................5
STORAGE .....................................................................................................................................................5
PRE-INSTALLATION INSPECTION ..............................................................................................................5
SEQUENCE OF OPERATION .......................................................................................................................6
Parallel Flow ...........................................................................................................................................6
Series Flow .............................................................................................................................................6
INSTALLATION .............................................................................................................................................6
Clearances .............................................................................................................................................7
Hanging and Mounting Equipment Overhead ....................................................................................7
Duct Connections ..................................................................................................................................7
Critically Sound Applications ...............................................................................................................7
Coil Connections ...................................................................................................................................8
Electrical .................................................................................................................................................8
OPERATION ..................................................................................................................................................8
Start-Up ..................................................................................................................................................8
Power Requirements ...........................................................................................................................8
Primary Air Damper and Fan Adjustment ...........................................................................................8
Series Flow, PSC Motor with SCR .......................................................................................................9
Parallel Flow, PSC Motor with SCR .....................................................................................................9
Series Flow ECM Motor Balancing ....................................................................................................10
Commissioning ....................................................................................................................................10
Balancing .............................................................................................................................................10
Manual Fan CFM Adjustment ............................................................................................................. 11
Remote Fan CFM Adjustment ............................................................................................................11
Status LED ...........................................................................................................................................11
MAINTENANCE ..........................................................................................................................................11
Factory Provided Damper Actuator ...................................................................................................11
Damper Shaft .......................................................................................................................................11
Motor/Blower ........................................................................................................................................11
Cleaning ..........................................................................................................................................12
Replacement ...................................................................................................................................12
Coil ........................................................................................................................................................12
Cleaning ..........................................................................................................................................12
Replacement ...................................................................................................................................12
Electric Heat .........................................................................................................................................13
Replacement ...................................................................................................................................13
TROUBLESHOOTING GUIDELINES .........................................................................................................14
ECM SPECIFIC TROUBLESHOOTING GUIDELINES ...............................................................................15
Checking ECM Cables .........................................................................................................................15
VALVE CALIBRATION CHARTS ...............................................................................................................17
FAN CFM CALIBRATION CURVES - TABLE 3 ..........................................................................................18
IN-WARRANTY RETURN PROCEDURE ...................................................................................................19
SERIES FLOW TERMINAL UNIT WEIGHTS -TABLE 4 .............................................................................19
PARALLEL FLOW TERMINAL UNIT WEIGHTS - TABLE 5 ......................................................................20
REPLACEMENT PARTS LIST ....................................................................................................................20
2
JOHNSON CONTROLS
FORM ET130.13-NOM3 (708)
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
DANGER indicates an im mi nent ly
hazardous situation which, if not
avoid ed, will re sult in death or se ri ous
injury.
WARNING indicates a potentially
haz ard ous sit u a tion which, if not
avoid ed, could result in death or se ri ous in ju ry.
CAUTION identifi es a hazard which
could lead to damage to the ma chine,
damage to other equip ment and/or
en vi ron men tal pollution. Usually an
in struc tion will be given, together with
a brief ex pla na tion.
NOTE is used to highlight ad di tion al
information which may be helpful to
you.
JOHNSON CONTROLS
3
FORM ET130.13-NOM3 (708)
SAFETY CONSIDERATIONS
The equipment covered in this manual is designed for
safe and reliable operation when installed and operated
within its’ design specifi cation limits. To avoid personal
injury or damage to equipment or property while
installing or operating this equipment, it is essential
that qualifi ed, experience personnel familiar with local
codes and regulations, perform these functions using
good judgment and safe practices. See the following
cautionary statements.
ELECTRICAL SHOCK HAZARDS
All power must be disconnected prior
to installation and servicing this equipment. More then one source of power
may be present. Disconnect, tag and
lock out all power sources to avoid
electrocution or shock hazards.
ROTATING EQUIPMENT HAZARD
Fans may start automatically. Disconnect all power and control circuits
prior to servicing to avoid injury.
Caution should be exercised due to the
possibility of fans “free wheeling” due
to connected duct air movement.
HOT PARTS HAZARD
Electric heaters may start automatically. Disconnect all power and control circuits prior to servicing to avoid
burns.
Check that rigging and lifting equipment can safely support the equipment
assembly and component weights.
All assemblies must be adequately
secured during lifting and rigging
by temporary supports and restraints
until equipment is permanently fastened and set in its’ fi nal location per
manufacturer’s guidelines.
All temporary and permanent equipment supports must be capable of
safely supporting the equipment’s
weight as well as any additional live,
seismic or dead loads that may be
encountered. All supports must be
designed to meet applicable local codes
and ordinances.
All fastening devices must be designed
to mechanically lock the assembly in
place without the capability of loosening or breaking away due to system
operation and vibration.
Dampers may activate automatically.
Disconnect the control circuits or
pneumatic control systems and secure
all dampers when servicing damper,
actuators or linkage to avoid injury.
Wear the appropriate personal protective equipment (gloves, safety glasses,
leather closed toe shoes, etc) when
handling this equipment recognizing
that sheet metal components are being
handled.
4
JOHNSON CONTROLS
FORM ET130.13-NOM3 (708)
INSPECTION
Upon receipt of equipment, carefully check all items
against the bill of lading to ensure that all equipment has
been received (including shipped loose items). Note any
discrepancy on the bill of lading before signing. Note
that “ship loose” items may be included with the base
unit or shipped (bulk) on a separate pallet.
Inspect all equipment for any signs of damage caused
during transit. On equipment with electric heat, make
sure to check the coil fi ns and/or make sure that the
resistance heat coils are not damaged. Note any
visual damage on the bill of lading before signing.
Immediately report all visual and concealed damage
to the carrier and fi le a claim with the carrier.
Locate the model number on the nameplate and check
that the correct equipment has been received. Verify
that all options have been included, such as controls,
fi lters, heating coils, etc. Also check that equipment
voltage agrees with the building parameters. If a
discrepancy is discovered between what was ordered and
received, contact your local Enviro -Tec representative
immediately.
Do not use fl ow sensor, connecting
tubes, coil stubouts or damper shaft
as a handle when lifting or moving
equipment as damage may occur.
Do not handle by equipment’s heating elements, as permanent damage
will occur.
Do not work on damper until associated actuator is disconnected.
Never pressurize equipment above
specifi ed test pressure.
Protect adjacent fl ammable materials
when brazing. Use fl ame and heat
protection barriers where need. Have
a fi re extinguisher at hand and ready
for immediate use.
STORAGE
If equipment is to be stored prior to installation, observe
the following precautions:
1. Choose a dry storage site that is reasonably level
and sturdy to prevent undue stress or permanent
damage to the equipment. Set equipment off
ground if in moisture prone areas.
2. Cover entire equipment with protective tarp or
moisture proof cover. Extend cover under equipment if stored on ground. Secure cover with
adequate tie downs. Be sure that piping connections have protective shipping caps installed.
3. Do not stack equipment any higher than how
it was shipped. If equipment has been unpackaged since receipt from the factory, do not stack
without equivalent support between units as was
supplied from the factory.
Check assembly and component
weights to be sure that the rigging
equipment can handle them safely.
Note; also check the centers of gravity
and any specifi c rigging instructions.
Check for adequate ventilation so
fumes do not migrate through ductwork
to occupied spaces when welding or
cutting around the equipment.
JOHNSON CONTROLS
PRE-INSTALLATION INSPECTION
Do not use fl ow sensor, connecting
tubes, coil stubouts or damper shaft
as a handle when lifting or moving
equipment as damage may occur.
Do not handle by equipment’s heating elements, as permanent damage
will occur.
5
FORM ET130.13-NOM3 (708)
While viewing the damper from the discharge of the
equipment, disengage the actuator by depressing the
manual override button on the side of the actuator and
rotate the shaft fully. The damper should close fully and
there should be no gaps between the damper gasketing
and the inside of the valve.
Units equipped with ECM or 1 horsepower motors will
ship from the factory with a removable motor / wheel
support installed in the fan housing. It is imperative that
this shipping support be removed prior to equipment
startup or damage may result to both the motor and the
wheel. A label will be affi xed to the outside of the unit
next to the power entry point, to identify the presence
of this shipping insert.
Manually rotate the fan wheel to assure that there are
no obstructions within the fan housing.
Equipment supplied with ECM motors, backward or reverse rotation of
the blower is detrimental to the ECM
motor.
SEQUENCE OF OPERATION
All fan-powered equipment is supplied with a rectangular
discharge and comes in one of two confi gurations:
1. Parallel fl ow with hot water coils mounted on the
plenum induction air opening.
2. Series fl ow with hot water coils mounted on the
discharge opening.
Either the primary air valve, fan or
both can deliver airfl ow to the occupied
space. A back draft damper is provided,
when the fan is not operating. The effi ciency of this system is the same as
standard single duct VAV equipment.
In a typical control sequence applied to parallel fl ow
equipment, the air valve is closed to a zero minimum
airfl ow before the fan is energized. After the fan has
been energized, the reheat will be energized upon a
further drop in space temperature. Therefore, little
primary air is mixed with the heated air stream.
Series Flow
Fan must be energized prior to introduction of air through the primary
air valve or the possibilities exist that
the fan wheel will operate backwards
/ counter rotation.
On series fl ow equipment, the fan runs continuously
whenever the central air handler is in operation.
In response to the space temperature, the air valve
modulates the volume of primary air. The re-heat is
typically off during the air valve’s modulation. Should
the space temperature decrease to the point at which a
decrease in primary air will not maintain the desired
temperature, the reheat will be activated to increase the
discharge air temperature.
INSTALLATION
Note that for either confi guration, electric heaters (if
supplied) are always mounted on the unit discharge
opening.
Parallel Flow
On parallel flow equipment, the primary air valve
delivers cooled air to the equipment’s outlet. When the
space temperature decreases beyond the control of the
primary air valve, the fan is started along with the fi rst
stage of heat. The fan delivers warm plenum air from
the controlled space to the equipment’s outlet, which
is mixed with the primary air prior to being delivered
to the space.
6
Do not use fl ow sensor, connecting
tubes, coil stubouts or damper shaft
as a handle when lifting or moving
equipment as damage may occur.
Do not handle by equipment’s heating elements, as permanent damage
will occur.
JOHNSON CONTROLS
FORM ET130.13-NOM3 (708)
Terminal equipment with electric heat must be installed
in a horizontal plane with respect to the air stream. Low
height equipment can be flipped over in the field to vary
or change control section handing.
Consult factory for application utilizing mercury contactors.
Clearances
All equipment covered in this document, including
those with electric heat, are ETL listed for 0.0”
clearance to combustibles. Refer to NEC and/or local
codes for minimum electrical clearances required for
service. Equipment should not make contact with any
structure located above or below the equipment without
appropriate isolation. Equipment supplied with bottom
access panels requires sufficient clearance to remove
access panels for service.
Duct Connections
All duct connections should be configured and installed
in accordance with SMACNA guidelines and all local
code requirements. Check to see that duct fasteners are
appropriate for the application and do not impinge any
internal components. Pay particular attention to internal
electrical components.
Fasten and seal all ductwork connections in accordance
with project specifications.
Allow a minimum of 1½ duct diameters of straight
duct prior to equipment inlet and after equipment
discharge.
The diameter of the inlet duct for round valves must
be equal to the listed size of the equipment. The round
air valve inlet collar of the equipment is 1/8” smaller
then listed size in order to allow the round ductwork to
slip over the air valve inlet collar.
DO NOT INSERT
DUCTWORK INTO AIR VALVE INLET COLLAR.
Hanging and Mounting Equipment Overhead
Johnson Controls strongly recommends that all
equipment be suspended from the upper most ceiling or
a structural element of the building, independent of the
false ceiling grid. Suspension devices are field supplied,
sized and designed by others. Johnson Controls will not
accept responsibility for equipment mounting supports.
Equipment must be installed in a level horizontal plane.
Failure to level equipment properly may prevent proper
operation of controls. See Tables 3 and 4 for equipment
weights.
When requested, equipment is supplied with optional
hanger brackets for use with (up to) a 3/8” [10mm]
diameter hanger rod. See submittal drawings for hanger
bracket locations.
Hanger straps may be utilized as an alternate means of
suspending the equipment. Do not secure hanger straps
to electric heaters, coils or control enclosures. Hanger
straps can be mounted directly to the sides and bottom
of equipment casing, such that they do not interfere with
working components or access panels using screws that
are no longer than 1” [25mm].
When hanging equipment, always use the support
method as prescribed for rectangular duct in the job
specifications.
When making ductwork connection to air valve inlet
collar and insulating air valve inlet, take caution not to
damage or remove the flow sensor connections, which
are vital to equipment control.
Provide insulation around entire inlet collar (all the way
to the equipment casing).
Cut “slits” in the insulation for the flow tubes and secure
with duct tape.
Permissible discharge duct connections are straight
flanged, slip and drive or drive and screw.
If equipment is to be installed in a location with high
humidity, external insulation around the heating coil
should be installed.
After all connections are made, check that the entire
ductwork system is airtight. In some high-pressure
systems, duct sealer may be necessary.
Sound Critical Applications
Flexible duct connectors are not recommended on
equipment discharge. The sagging membrane of
these fittings can cause turbulence and locally high
air velocities that generate noise. Also, lightweight
membrane material allows noise to breakout, which can
increase sound levels in the space below.
JOHNSON CONTROLS
7
Coil Connections
FORM ET130.13-NOM3 (708)
Power Requirements
Hot water and steam coils are male sweat connection.
Use appropriate brazing alloy for system temperature
and pressure. Refer to equipment construction submittal
drawing for specifi c connection size. MAXIMUM
HYDRONIC SYSTEM OPERATING PRESSURE
MUST NOT EXCEED 300 PSIG. MAXIMUM
STEAM SYSTEM PRESSURE MUST NOT
EXCEED 15 PSIG.
If necessary, you can change coil connection handing on
one and two row coils from left-hand to right-hand (and
vice-versa) by rotating the coil “like a steering wheel”
180° about its central axis when facing the fi ns. For
three and four row coils, consult factory.
Electrical
All fi eld wiring must comply with NEC and all local
codes. Electrical and control diagrams are affi xed to the
interior of the control enclosure box.
Minimum circuit ampacity (MCA) designates the
maximum operating load of the equipment for sizing
wire feeders. Supply Circuit Protection designates the
largest breaker in the electrical service panel that can
be used to protect the equipment.
Use Copper conductors only.
OPERATION
Start-Up
Thorough safety precautions should always be taken
when performing startup and service. Refer to safety
considerations at the beginning of this Operation
Manual. Only qualifi ed individuals should perform
these tasks.
Prior to start-up, the project control sequence/wiring
diagram should be obtained and thoroughly understood.
If factory supplied analog or DDC controls are utilized,
refer to the applicable Operation Manual for start-up
and balancing information. Check that all electrical
work is fi nished and properly terminated. Check that
all electrical connections are tight and that the proper
voltage is connected.
Three Phase AC power imbalance must not exceed 2%.
Be sure that the following guides are met:
1. AC power is within 10% of rated voltage at rated
frequency. (See equipment nameplate for rat-
ings)
2. AC power is within 5% of rated frequency at rated
voltage.
3. A combined variation in the voltage and frequency
of 10% (sum of absolute values) of rated values
provided the frequency variation does not exceed
5% of rated frequency.
Primary Air Damper and Fan Adjustment
Unit should not be balanced until the incoming power
supply is at the permanent voltage condition. All
discharge ductwork must be connected. The minimum
recommend discharge static pressure for all fan-powered
equipment is 0.1” wg. and 0.2” on 3/4hp and larger
(see fan curves located on the Enviro -Tec web site for
specifi cs). All foreign materials should be removed
from the duct system. Optional filters should be
installed as required.
Unless otherwise specifi ed, the fan motor has three
speeds. Fan speed is selected in the electrical control
enclosure by one of two methods. For units with dual
motors, see Figure 1A showing how the fan speed is
selected by placement of a factory supplied jumper
wire on a terminal strip. Otherwise see Figure 1B
which shows the wire to wire fan speed selection
method. Simply insert the male quick connect (from
control circuitry) into the female quick connect which
corresponds to high (black), medium (blue), or low (red)
motor speeds. Units are set to low speed at the factory
as standard in order to optimize energy effi ciency. A
three position rotary switch is optional.
ELECTRICAL SHOCK HAZARD
All power must be disconnected prior
to changing jumper or serious injury
or death will result.
Check to make sure that heater elements are not
damaged, free of all foreign material and proper control
interlocks have been made before energizing the electric
heater.
8
All fan-power equipment is shipped with an electronic
solid state fan speed controller (SCR) for PSC motors.
The SCR is located in the control enclosure. Using
a 1/8” fl at blade screwdriver, adjusting the manual
potentiometer clockwise will increase the motor speed;
adjusting the potentiometer counterclockwise will
decrease the motor speed.
JOHNSON CONTROLS
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