Greenheck VARI-FLOW, FX15 User Manual

Part #472966

Vari-Flow Air

Management System

Installation, Operation and Maintenance Manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions

product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

could result in personal injury and/or property damage! Retain instructions for future reference.

HOOD

LIGHTS

FAN

100%

FAN

ON/OFF

SYSTEM

FAULT

472621

General Safety Information

Only qualiﬁed personnel should install this unit. Personnel should have a clear understanding of these instructions and should be aware of general safety precautions. Improper installation can result in electric shock, possible injury due to coming in contact with moving parts, as well as other potential hazards. Other considerations may be required if high winds or seismic activity are present. If more information is needed, contact a licensed professional engineer before moving forward.

1. Follow all local electrical and safety codes, as well as the National Electrical Code (NEC), the National Fire Protection Agency (NFPA), where applicable. Follow the Canadian Electric Code (CEC) in Canada.

2. Do not allow the power cable to kink or come in contact with oil, grease, hot surfaces, or chemicals. Replace cord immediately if damaged.

3. Verify that the power source is compatible with the equipment.

DANGER

Always disconnect power before working on or near a unit. Lock and tag the disconnect switch or breaker to prevent accidental power up.

CAUTION

When servicing the unit, variable frequency drives (VFD’s) may be hot enough to cause pain or injury. Allow motor to cool before servicing.

Vari-Flow Air Management Systems

Table of Contents

Receiving and Handling. . . . . . . . . . . . . . 2

Installation

Control Box Mounting . . . . . . . . . . . . . 3

Resistive Temperature Detector . . . . . . . . 3

Pneumatic Static Pressure Kit . . . . . . . . . . 4

Keypad Mounting . . . . . . . . . . . . . . . . . 4

Wiring . . . . . . . . . . . . . . . . . . . . . . . 5

Wiring Diagrams . . . . . . . . . . . . . . . . 6-7

Connection Checklist . . . . . . . . . . . . . . . 8

Controller Setup . . . . . . . . . . . . . . . . . 8

Controller Display . . . . . . . . . . . . . . . 9-12

Sequence of Operations . . . . . . . . . . . . 13

Daily Operations . . . . . . . . . . . . . . . . 14

System Optimization . . . . . . . . . . . . . . 14

Troubleshooting . . . . . . . . . . . . . . . . 15

Warranty . . . . . . . . . . . . . . . . . . . . . 16

Receiving

Upon receiving the product check to make sure all items are accounted for by referencing the bill of lading to ensure all items were received. Inspect each crate for shipping damage before accepting delivery. Notify the carrier if any damage is noticed. The carrier will make notiﬁcation on the delivery receipt acknowledging any damage to the product. All damage should be noted on all the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report should be ﬁlled out by the carrier upon arrival and the Trafﬁc Department. If damaged upon arrival, ﬁle claim with carrier. Any physical damage to the unit after acceptance is not the responsibility of Greenheck Fan Corporation.

Unpacking

Verify that all required parts and the correct quantity of each item have been received. If any items are missing, report shortages to your local representative to arrange for obtaining missing parts. Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space. Conﬁrmation of shipment(s) must be limited to only items on the bill of lading.

INDOOR — The ideal environment for the storage of

units and accessories is indoors, above grade, in a low humidity atmosphere which is sealed to prevent the entry of blowing dust, rain, or snow. Temperatures should be evenly maintained between 30°F (-1°C) and 110°F (43°C) (wide temperature swings may cause condensation and “sweating” of metal parts). All accessories must be stored indoors in a clean, dry atmosphere.

Remove any accumulations of dirt, water, ice, or snow and wipe dry before moving to indoor storage. To avoid “sweating” of metal parts, allow cold parts to reach room temperature. To dry parts and packages use a portable electric heater to get rid of any moisture build up. Leave coverings loose to permit air circulation and to allow for periodic inspection.

The unit should be stored at least 3½ in. (89 mm) off the ﬂoor on wooden blocks covered with moisture proof paper or polyethylene sheathing. Aisles between parts and along all walls should be provided to permit air circulation and space for inspection.

Inspection and Maintenance during Storage

While in storage, inspect equipment once per month. Keep a record of inspection and maintenance performed.

If moisture or dirt accumulations are found on parts, the source should be located and eliminated.

REMOVING FROM STORAGE — As units are removed

from storage to be installed in their ﬁnal location, they should be protected and maintained in a similar fashion, until the equipment goes into operation.

Prior to installing the unit and system components, inspect the unit assembly to make sure it is in working order.

1. Check all fasteners, and accessories for tightness.

Handling

Handle in such a manner as to keep from scratching or chipping the coating. Damaged ﬁnish may reduce ability of unit to resist corrosion.

Storage

Units are protected against damage during shipment. If the unit cannot be installed and operated immediately, precautions need to be taken to prevent deterioration of the unit during storage. The user assumes responsibility of the unit and accessories while in storage. The manufacturer will not be responsible for damage during storage. These suggestions are provided solely as a convenience to the user.

Vari-Flow Air Management System

Installation

1/4 inch Compression Seal

Gasket

1/4 inch Compression Seal

Gasket

Temperature Sensor

Lock Washer

Nut

Octagon Cover

Exhaust Area

.75 to .875 inch diameter hole

Hood Surface

1/4 inch Compression Seal

Gasket

Temperature Sensor

Lock Washer

Nut

Octagon Cover

Control Box Mounting

1. Locate an area with enough space to mount the control box and fasten to the wall.

NOTE

Control Box may be factory mounted. If so, continue to the next section.

NOTE

As the control box contains the static pressure controls, this control box should be mounted in the space to be controlled. If the control box is mounted outside of this space, please refer to the Pneumatic Static Pressure Kit Installation Instructions.

Resistive Temperature Detector(s) (RTD) Mounting

NOTE

Resistive temperature detector(s) may be factory installed. If so, continue to the next section.

1. Locate ﬂat area(s) at the top interior of the hood in front of the ﬁlters, towards the front of the hood.

2. Insert the compression seal into the hole from the inside of the hood, making sure the gasket is placed on the ﬁtting before inserting it into the hole. Install the lock washer and 1-1/2 inch nut on the threaded portion of the compression seals and tighten securely.

1/4 inch Compression Seal

Gasket

Temperature Sensor

Lock Washer

Nut

Octagon Cover

3. Place the octagon box provided over the ﬁtting on top of the hood, keeping the ﬁtting centered in the box.

4. Insert the resistive temperature detector (RTD) into compression seal and tighten to 35 ft-lbs.

Exhaust Area

Sensor Install

Cut Out Area

Supply Area (optional)

Top View of Exhaust Hood

Cut a 3/4-inch diameter hole into the top of

the capture tank. Make sure the resistive temperature detector(s) will not interfere with ﬁre system nozzles and is not within 12 inches of light ﬁxtures.

.75 to .875 inch diameter hole

Hood Surface

Center the octagon extension over the hole on

the hood surface.

NOTE

All ﬁeld installation and wiring of electrical equipment must be done to meet NEC and local codes.

Octagon Extension

Vari-Flow Air Management System

Pneumatic Static Pressure Kit

Keypad Mounting

1. Locate the Dwyer static pressure sensor outside of the building in a secure location free from as many obstructions as possible.

2. Refer to the instruction manual with the static pressure sensor for installation and operation details.

3. Once the static pressure probe is mounted, run vinyl tubing from the probe back to the control panel and coil the excess tubing. Do not kink or trim the tubing.

4. If the control panel is located in the space to be controlled, go to the next section. If the control panel is mounted remotely from the space to be controlled, continue to step 5.

5. Run 1/4 inch virgin poly tubing (by others) from the sensor in the control panel to a secure location in the space to be controlled.

NOTE

The keypad may be factory mounted. If so, continue to the next section.

1. For systems with remote controls or keypad, a 25 ft. cable is supplied to connect the keypad to the controls. The cable is plenum rated and does not need to be run through conduit unless required by local codes. If the keypad is to be mounted further than 25 ft. from the control box, additional cable will be needed. Cable is available in 25 ft. lengths from the factory.

Keypad Mounting Diagram

Connection made at top of Control Panel

If desired, conduit and ﬁttings supplied by others in ﬁeld. One-inch conduit needed to allow smaller connector to ﬁt through.

Keypad, screws and wire harness supplied by the factory

25 ft. cable assembly supplied by the factory

Two-gang switch box supplied by the factory

KEYPAD

Vari-Flow Air Management System

51 - DO4

45 - DO2

22 - DI COM

24V (C) - 92

DO1 COM - 41

DO4 COM - 53

24VAC

120VAC

RED

Fault Indicator

GRN

Full Speed Indicator

Hood Lamp(s)

Hood Light Contactor

TR1

Hood Lights Switch

PB1

2 3

Hood Lights Relay

Hood Run Contact

1411

GRN

Canopy Lighting circuit must not exceed 15A total current

AVPS - 13

31 - DI7

Fan Override

NOC

PS1

PRESSURE

Hood Light LED

Relay

A1 A2

Hood Light LED Contact

1411

GRN

DO2 COM - 44

BK 14GA

16GA RD 16GA RD

NEUTRAL

AI6 - 15

1 - AICOM

AICOM - 1

120 VAC

24 VAC

Fire System

REMOVE

JUMPER

IF USED

Fire & Shunt

Trip Relay

24 VAC

Full Speed

Fan On/O

PB3

PB2

9 13

Fan Override

PS1

PRESSURE

NEUTRAL

Fire Contact

Fire System

35 34

REMOVE JUMPER IF USED

Fire & Shunt Trip Relay

24 VAC

PR PR

DI COM-22

DI2-23

DI3-25

24V (C)-92

DO1 COM-41

DO4 COM-53

DI1-21

AVPS-13

DI7-31

DO2 COM-44

AI6-15

AICOM-1

AO1-72

AO COM-71

AO2-74

AO3-76

DI COM-22

DI4-26

AOV COM-79

DIV COM-34

DO3 COM-47

VFD

LINELOAD

EF1

LINELOAD

VFD

EF2

LINELOAD

}

Wiring

NOTE

All ﬁeld installation and wiring of electrical equipment must be done to meet NEC and local codes.

Control Box

1. Run power to the control box from two dedicated 120/1 20A breakers to the designated terminals in the control box (one for lights, one for controls).

2. If the variable frequency drives(s) are shipped loose from the control cabinet, please refer to the VFD wiring section for connection instructions to the control box.

3. For hood systems connected to a ﬁre system,

Resistive Temperature Detectors (RTD)

1. Wire the two leads of the sensors to designated

the ﬁre system microswitch can be wired into the designated terminals of the control box for integration of ﬁre system controls. The factory default is exhaust on, supply off in ﬁre mode. For help with changing this parameter, please refer to the controller setup portion of this manual.

terminals in the control panel as shown below. For more than four sensors, see wiring diagram on page 7 or the one inside of control box door. The two wires of the sensor are not polarity sensitive. If more than one hood is being controlled, be sure that the appropriate sensor is wired in association with the appropriate hood.

The RTD’s should not be exposed to direct ﬂame. The RTD’s are rated up to 250°F

NOTE

Variable Frequency Drives (VFD)

NOTE

If the VFD(s) are factory supplied and mounted in a cabinet, all interface wiring is factory supplied and this ﬁrst step can be disregarded.

NOTE

If electrically commutated motors are being used, VFDs will not be needed.

1. If the variable frequency drives are remotely mounted, a six conductor 18 ga. Class 2 cable must run between each VFD and the control panel.

2. Bring power to the input of each VFD from a dedicated power source using conduit. Each power source shall be of the same voltage as the respective fan and of a high enough amp rating to handle the full load amp draw of the respective fan.

NOTE

The VFD input voltage parameter (E1-01) and motor overload parameter (E2-01) need to be set to the motor nameplate FLA. Refer to the Quick Start Guide from Yaskawa (pages 83-100) for setting these parameters on the Yaskawa drive.

Be sure to use appropriately sized wire for the full load amp draw.

3. To avoid interference between the conductors, use separate conduit to wire from the VFD output to the input power for the fan.

24 VAC FAN ENABLE

}

Vari-Flow Air Management System

TO MUA

24V (H)-93

2 - AI1

5 - AI2

7 - AI3

10 - AI4

24V (C)-92

DI COM-22

AO COM-71

AO4-78

DI5-28

}

VFD

MUA1

LINE

LOAD

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