Greenheck VARI-FLOW, FX15 User Manual

Part #472966

®

®

Vari-Flow Air

Management System

Installation, Operation and Maintenance Manual

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

1

®

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

2

®

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

3

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

4

®

U1

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)

AR

Hood Light Contactor

TR1

L4

L3

Hood Lights Switch

PB1

AR

2 3

6

Hood Lights Relay

R1

Hood Run Contact

1411

GRN

L1

7

4

6

15

H1

N1

Canopy Lighting circuit must not exceed 15A total current

AVPS - 13

31 - DI7

Fan Override

33

32

NOC

PS1

PRESSURE

1

2

3

R5

Hood Light LED

Relay

A1 A2

R5

Hood Light LED Contact

1411

GRN

L2

2

HL

DO2 COM - 44

G

BK 14GA

16GA RD 16GA RD

BL

OR

OR

PR

YW

OR

+

-

0

NEUTRAL

AI6 - 15

1 - AICOM

BR

AICOM - 1

120 VAC

24 VAC

Fire System

35

REMOVE

JUMPER

IF USED

R4

Fire & Shunt

Trip Relay

A1

A2

24 VAC

BR

YW

OR

OR

OR

OR

OR

PR

Full Speed

Fan On/O

PB3

PB2

9 13

11

Fan Override

33

32

PS1

PRESSURE

1

2

3

PR

YW

OR

+

-

o

NEUTRAL

R1

24

21

R4

14

11

Fire Contact

48

49

50

51

Fire System

35 34

REMOVE JUMPER IF USED

R4

Fire & Shunt Trip Relay

A1

A2

24 VAC

YW

YW

BR

YW

OR

OR

OR

PR

PR

PR

PR PR

PR

PR

OR

BR

RD

RD

34

31

58

59

54

55

56

57

OR

RD

RD

R1

OR

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

YW

YW

YW

52

53

24

21

MC

MB

SC

S1

AC

A1

VFD

L1

L2

L3

T1

T2

T3

LINELOAD

EF1

AC

A1

MC

MB

SC

S1

L1

L2

L3

T1

T2

T3

LINELOAD

VFD

EF2

MC

MB

SC

S1

L1

L2

L3

T1

T2

LINELOAD

AC

R2

14

11

64

60

61

62

63

RD

RD

}

}

}

}

}

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

16

18

20

22

®

T1

T3

NOTE

T2

T4

17

19

21

23

OR

OR

OR

OR

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

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.

42

24 VAC FAN ENABLE

}

43

38

39

40

41

47

46

Vari-Flow Air Management System

TO MUA

MC

MB

SC

S1

AC

A1

24V (H)-93

2 - AI1

5 - AI2

7 - AI3

10 - AI4

24V (C)-92

DI COM-22

AO COM-71

AO4-78

DI5-28

BL

R3

YW

PR

PR

R3

BR

OR

11

14

RD

RD

L1

L2

}

L3

T1

T2

}

T3

VFD

MUA1

LINE

LOAD

5

Wiring Diagram - Base System, all options

Canopy lighting circuit must not exceed 15A total current

H

G

PR

BK 14GA

AR

NOC

H1

Hood Light Contactor

HL

16GA RD 16GA RD

TR1

120VAC

R5

A1 A2

Hood Light LED Relay

120 VAC

N

N1

Hood Lamp(s)

BK

BL

24 VAC

Hood Lights Relay

15

6

2

7

4

}

+ VDC

COM

}

AR

2 3

BL

OR

OR

1716

1918

2120

2322

V1

VC

44

45

6

Hood Light LED Contact

OR

OR

BR

OR

OR

OR

OR

BL

BL

BL

BL

YW

YW

OR

BR

PR

PR

BL

R4

22

21

A1 A2

Hood Run

PB1

Hood Lights Switch

Hood Run Indicator

Hood Light Indicator

L3

RED

Fault Indicator

Full Speed Indicator

R1

24 VAC

A1 A2
Hood Run

R3

24 VAC

A1 A2

MUA Run

GGH20/VAV Fan Mode
Interlock Connection

0VDC - Fan Auto
5VDC - Fan OFF

10VDC - Fan On for Dry

Tempering Status Contact

Closed Tempering On
Open Tempering O

RD

36

}

RD

37

L1

GRN

L2

GRN

L4

GRN

T1

T3

R2

24 VAC

REMOVE JUMPER

Shunt Trip Contact

Closes on Shunt Trip

T2

T4

IF USED

BL

BL

BL

BL

BL

BL

14

1

R1

Hood Run Contact

R5

51-DO4

45-DO2

1-AICOM

2-AI1

5-AI2

7-AI3

10-AI4

35-DIV HOT

80-AOV HOT

93-24V (H)

42-DO1

48-DO3

12-AI5

1-AICOM

30-DI6

29-DI COM

24VAC

1411

1411

U1

AVPS-13

DO2 COM-44

DO4 COM-53

AI6-15

AICOM-1

24V (C)-92

DO1 COM-41

AOV COM-79

DIV COM-34

DO3 COM-47

DI COM-22

DI7-31

DI2-23

DI1-21

DI3-25

DI COM-22

AO COM-71

AO1-72

AO2-74

AO3-76

DI4-26

24V (H)-93

24V (C)-92

DI COM-22

DI5-28

AO COM-71

AO4-78

EARTH-91

OR

OR

OR

OR

BR

YW

YW

YW

YW

YW

PR

PR

32

PR

PR

11

PR PR

PR

BR
OR

OR

OR

PR

BL

YW

PR

PR

R3

BR

OR

GN

33

PB3

9 13

PB2

R4

11

14

Fire Contact

24

21

42

R3

}

43

38

39

RD

11

40

14

RD

41

47

46

Fan Override

Full Speed

Fan On/O

24 VAC FAN ENABLE

TO MUA

MC

MB

SC

S1

AC

A1

VFD

MUA1

1
+

3
o

PRESSURE

L1

L2

}

L3

T1

T2

}

T3

R4

A2

A1

Fire & Shunt Trip Relay

24 VAC

2

NEUTRAL

-

PS1

LINE

LOAD

Fire System

35 34

REMOVE JUMPER IF USED

48

49

RD

50

24

R1

RD

21

51

52

53

54

55

RD

56

34

R1

RD

31

57

58

59

60

61

RD

14

62

R2

11

63

RD

64

65

YW

YW

YW

YW

MC

L1

L2

MB

}

LINELOAD

L3

SC

S1

T1

AC

T2

}

A1

T3

VFD

EF1

MC

L1

L2

MB

}

SC

S1

AC

A1

MC

MB

SC

S1

AC

A1

LINELOAD

L3

T1

T2

}

T3

VFD

EF2

L1

L2

}

LINELOAD

L3

T1

T2

}

T3

VFD

EF3

NOTE

This is an example of a wiring diagram for a base system. Controlling up to 3 exhaust fans, 1 supply fan and 4
temperature sensors. To see your job specific drawing, look on the inside panel of the Vari-Flow cabinet.

Vari-Flow Air Management System

6

®

Wiring Diagram - Expanded System, all options

Canopy lighting circuit must not exceed 15A total current

H

G

PR

BL

BL

RT+

RT-

COM

24 VAC

TB1

14

J1

A1
Hood Run

22

R4

21

PB1

Hood Lights Switch

L3

RED

Fault Indicator

R1

24 VAC

A2

R3

24 VAC

A2

A1
MUA Run

GGH20/VAV Fan Mode
Interlock Connection

0VDC - Fan Auto
5VDC - Fan OFF
10VDC - Fan On for Dry

Tempering Status Contact

RD

36

RD

37

U2

BL BL

BL

1

BL

BL

BL

BL

BL

XT91D00

Note: 4-wire
jumper assembly

H1

L1

GRN

Hood Run Indicator

L2

GRN

Hood Light Indicator

L4

GRN

Full Speed Indicator

T1

T3

R2

24 VAC

A1

A2

Hood Run

REMOVE JUMPER

Closed Tempering On
Open Tempering O

Shunt Trip Contact

Closes on Shunt Trip

}

YW

TB1

COM

24 VAC

BL

CN1 CN2

1
2
3
4

BK 14GA

T2

T4

IF USED

24 VAC

1
2
3
4

TB1

COM

15

6

7

4

}

+ VDC

COM

XP91D02

AR

Hood Light Contactor

24 VAC

Hood Lights Relay

AR

2 3

OR

OR

2

1716

1918

2120

2322

V1

VC

44

}

45

U3

NOC

6

Hood Run Contact

Hood Light LED Contact

OR

51-DO4

OR

45-DO2

BR

1-AICOM

OR

2-AI1

OR

5-AI2

OR

7-AI3

OR

10-AI4

BL

35-DIV HOT

BL

80-AOV HOT

BL

BL

93-24V (H)

YW

42-DO1

YW

48-DO3

OR

12-AI5

BR

1-AICOM

PR

30-DI6

PR

29-DI COM

BR

COM

WT

LL-

RD

LL+

INPUTS

O7

OUTPUTS

O8

HL

16GA RD 16GA RD

TR1

120VAC

24VAC

R1

1411

R5

1411

U1

OR

I1

OR

I2

OR

I3

OR

I4

BR

BR

OR

AVPS-13

DO2 COM-44

DO4 COM-53

AI6-15

AICOM-1

24V (C)-92

DO1 COM-41

AOV COM-79

DIV COM-34

DO3 COM-47

DI COM-22

DI7-31

DI2-23

DI1-21

DI3-25

DI COM-22

AO COM-71

AO1-72

AO2-74

AO3-76

DI4-26

24V (H)-93

24V (C)-92

DI COM-22

DI5-28

AO COM-71

AO4-78

EARTH-91

24V (C)-92

T7

T5

Hood Lamp(s)

R5

A1 A2

Hood Light LED Relay

120 VAC

OR

OR

OR

OR

BR

YW

YW

YW

YW

YW

PR

PR

32

33

PB3

PR

9 13

PB2

PR

11

R4

PR PR

11

14

Fire Contact

PR

BR
OR

OR

OR

PR

24

21

BL

42

R3

YW

PR

PR

R3

BR

OR

GN

YW

}

43

38

39

RD

11

40

14

RD

41

47

46

T6

T8

24 VAC FAN ENABLE

TO MUA

MC

MB

SC

S1

AC

A1

2524

2726

2928

3130

Fan Override

Full Speed
Fan On/O

T2

T3

VFD

MUA1

1
+

3
o

PRESSURE

L1

L2

}

L3

T1

}

R4

A2

A1

Fire & Shunt Trip Relay

24 VAC

2

NEUTRAL

-

PS1

LINE

LOAD

N1

BK

Fire System

35 34

REMOVE JUMPER IF USED

48

49

RD

50

24

R1

RD

21

51

52

53

54

55

RD

56

34

R1

RD

31

57

58

59

60

61

RD

14

62

R2

11

63

RD

64

65

66

67

RD

24

68

R2

21

69

RD

70

71

72

73

RD

74

34

R2

31

75

RD

76

77

N

YW

YW

YW

YW

MC

L1

L2

MB

SC

S1

AC

A1

MC

MB

SC

S1

AC

A1

MC

MB

SC

S1

AC

A1

MC

MB

SC

S1

AC

A1

MC

MB

SC

S1

AC

A1

LINELOAD

}

L3

T1

T2

}

T3

VFD

EF1

L1

L2

}

LINELOAD

L3

T1

T2

}

T3

VFD

EF2

L1

L2

}

LINELOAD

L3

T1

T2

}

T3

VFD

EF3

L1

L2

}

LINELOAD

L3

T1

T2

}

T3

VFD

EF4

L1

L2

}

LINELOAD

L3

T1

T2

}

T3

VFD

EF5

NOTE

This is an example of a wiring diagram for an expanded system, controlling up to 5 exhaust fans, 8 temperature
sensors and 1 supply fan. For a job specific drawing, look on the inside panel of the Vari-Flow cabinet.

®

Vari-Flow Air Management System

7

Vari-Flow Connection Checklist

Controller Setup

Power to Vari-Flow Cabinet

 Connect 120 VAC power for controls

(terminals H, N)
Connect 120 VAC power for hood lights
(terminals H1, N1)
Connect lights
(terminals HL, N1)

Power to Variable Frequency Drive(s)

Line power to VFD input terminals L1/L2/L3
Load power from VFD output terminals T1/T2/T3

Fire System Interface

 Microswitch Common and Normally Closed

(terminals 34, 35)

Temperature Sensors

Temperature Sensor T1 (terminals 16, 17)
*If more than one temperature sensor is used,

wire the following if applicable.

Temperature Sensor T2 (terminals 18, 19)
Temperature Sensor T3 (terminals 20, 21)
Temperature Sensor T4 (terminals 22, 23)
Temperature Sensor T5 (terminals 24, 25)
Temperature Sensor T6 (terminals 26, 27)
Temperature Sensor T7 (terminals 28, 29)
Temperature Sensor T8 (terminals 30, 31)

Keypad - whether located on hood, hood cabinet, or
wall mounted.

 Connect provided cable from keypad to

control cabinet.

Make-Up Air Interface

 24 VAC Run Enable (terminals 42, 43) to make-up

air (terminals 42, 43)*
 Tempering Status (terminals 44, 45) to make-up

air (terminals 44, 45)*
 0-10 VDC Speed Reference (terminals 46, 47) to

make-up air (terminals 46, 47)*

 If using pressure mode, run tubing to adjacent
room or outside.

*Terminal numbers for Greenheck make-up air
units. If using alternate manufacturer’s make-up
air unit, consult manufacturer for needed terminal
connections.

Shunt Trip

 Normally open set of contacts to be used to shunt

appliances.

(if used)

(installed in hood)

This section details the process of entering the setup
controls of the programmable logic controller(s)
(PLCs). The controllers are factory set with standard
default values which are shown in the controller
settings table on pages 9-12.

Within the programmable logic controller, factory
set points can be modified to configure the system
for specific functions if necessary. To modify the
parameters, refer to the steps provided.

NOTE

For a complete list of all settings within the
Controller U1, please refer to the FX15 Vari-Flow
Controller Display tables on pages 9-12.

Up ESC

Left

Right

ReturnDown

Controller U1

1. To view factory default settings for the controller,
scroll through the respective controller menus
using the up and down arrow buttons.

2. To modify settings for a Controller U1, press
the escape (ESC) button on the controller to
navigate to the “Accounts” menu and follow the
subsequent steps.

3. Press return while “Accounts” is displayed.
When “User: GFC” appears, press the return
button.

4. Enter the first character of the password
(password is 3637) by using the up and down
arrow buttons. When the appropriate value is
displayed, press return. Continue until the entire
four digit password has been entered.

5. Once the password has been successfully
entered, press ESC and the display will return to
the main menu. Continue to scroll through the
menus using the left and right arrow buttons,
enter a menu by pressing the return button.
Scroll within the menus using the up and down
arrow buttons.

6. To back out of any menu, press the escape (ESC)
button.

Grease Grabber H2O Interface

 Grease Grabber H2O / Vari-Flow interface

(terminals V1, VC)

 Keypad interface (terminals 1, 3, 5, 7, 10, 13 to

terminals 1, 3, 5, 7, 10, 13)

Vari-Flow Air Management System

8

(if used)

®

FX15 Vari-Flow Controller Display

Accounts

Menu Descriptors/Value Default Use

Log In GFC GFC Password is 3637

Events

The events menu is empty unless a system fault
has occurred. If it has, then the system fault will
be listed in the events menu.

Temperature Sensors

Sensor Temperature

T1 °F - The temperature of sensor T1

T2 °F - The temperature of sensor T2

T3 °F - The temperature of sensor T3

T4 °F - The temperature of sensor T4

T5 °F - The temperature of sensor T5

T6 °F - The temperature of sensor T6

T7 °F - The temperature of sensor T7

T8 °F - The temperature of sensor T8

Temperature Sensor on EF1*

T1 to EF1 No / Yes Yes Indicates if T1 is linked to EF1

T2 to EF1 No / Yes No Indicates if T2 is linked to EF1

T3 to EF1 No / Yes No Indicates if T3 is linked to EF1

T4 to EF1 No / Yes No Indicates if T4 is linked to EF1

T5 to EF1 No / Yes No Indicates if T5 is linked to EF1

T6 to EF1 No / Yes No Indicates if T6 is linked to EF1

T7 to EF1 No / Yes No Indicates if T7 is linked to EF1

T8 to EF1 No / Yes No Indicates if T8 is linked to EF1

Temperature Sensor on EF2*

T1 to EF2 No / Yes No Indicates if T1 is linked to EF2

T2 to EF2 No / Yes No Indicates if T2 is linked to EF2

T3 to EF2 No / Yes No Indicates if T3 is linked to EF2

T4 to EF2 No / Yes No Indicates if T4 is linked to EF2

T5 to EF2 No / Yes No Indicates if T5 is linked to EF2

T6 to EF2 No / Yes No Indicates if T6 is linked to EF2

T7 to EF2 No / Yes No Indicates if T7 is linked to EF2

T8 to EF2 No / Yes No Indicates if T8 is linked to EF2

Temperature Sensor on EF3*

T1 to EF3 No / Yes No Indicates if T1 is linked to EF3

T2 to EF3 No / Yes No Indicates if T2 is linked to EF3

T3 to EF3 No / Yes No Indicates if T3 is linked to EF3

T4 to EF3 No / Yes No Indicates if T4 is linked to EF3

T5 to EF3 No / Yes No Indicates if T5 is linked to EF3

T6 to EF3 No / Yes No Indicates if T6 is linked to EF3

T7 to EF3 No / Yes No Indicates if T7 is linked to EF3

T8 to EF3 No / Yes No Indicates if T8 is linked to EF3

* To see values, you need to log in (see instructions on page 8).

®

Vari-Flow Air Management System

9

Temperature Sensors - continued

Temp Sensor on EF4* Descriptors/Value Default Use

T1 to EF4 No / Yes No Indicates if T1 is linked to EF4
T2 to EF4 No / Yes No Indicates if T2 is linked to EF4
T3 to EF4 No / Yes No Indicates if T3 is linked to EF4
T4 to EF4 No / Yes No Indicates if T4 is linked to EF4
T5 to EF4 No / Yes No Indicates if T5 is linked to EF4

T6 to EF4 No / Yes No Indicates if T6 is linked to EF4
T7 to EF4 No / Yes No Indicates if T7 is linked to EF4
T8 to EF4 No / Yes No Indicates if T8 is linked to EF4

Temperature Sensor on EF5*

T1 to EF5 No / Yes No Indicates if T1 is linked to EF5
T2 to EF5 No / Yes No Indicates if T2 is linked to EF5
T3 to EF5 No / Yes No Indicates if T3 is linked to EF5
T4 to EF5 No / Yes No Indicates if T4 is linked to EF5
T5 to EF5 No / Yes No Indicates if T5 is linked to EF5
T6 to EF5 No / Yes No Indicates if T6 is linked to EF5
T7 to EF5 No / Yes No Indicates if T7 is linked to EF5

T8 to EF5 No / Yes No Indicates if T8 is linked to EF5

Temperature Sensors Connected

T1 No / Yes Yes Indicates if T1 is connected
T2 No / Yes No Indicates if T2 is connected
T3 No / Yes No Indicates if T3 is connected
T4 No / Yes No Indicates if T4 is connected

Temperature Interlock (IMC Compliance)

Temp Interlock*

TempInt Enabled No/Yes Yes If set to yes, Temperature Interlock feature

is enabled. Exhaust fan will start if hood
temperature exceeds the Temperature Interlock
set point and will run until the hood temperature
falls below set point for the off delay time.

Set Point °F 90°F If the temperature of the hood exceeds this set

point, the exhaust fan will start automatically
regardless of the operating mode of the fan
selected by the operator.

Off Delay Time Minutes 10 min The amount of time the fans remain on after

the temperature in the hood goes below the
temperature set point.

Make-Up Air

Make-Up Air Set Points*

MUA Mode Pres / Trak Pres Indicates the operating mode of the MUA
Pressure Inches of WC x 100 - Differential air pressure measured from the

control space to the outside or adjacent room.

Set Point Inches of WC x 100 5 The desired space pressure set point.

(adjustable from -.30” WC to + .30” WC)
MUA Speed 0-100% - The actual output speed for the MUA
Max Speed Set* 0-100% 100% The maximum output control limit for the MUA

VFD or damper set. Must be set to a value

that ensures proper design full flow CFM.

(Adjustable from 0% to 100%)

* To see values, you need to log in.

Vari-Flow Air Management System

10

®

Make-Up Air - continued

Make-Up Air Set Point* Descriptors/Value Default Use

Min Speed Set 0-100% 50% The minimum output control limit for the MUA

VFD or damper. Must be set to a value that
ensures proper design full flow CFM (Adjustable
from 0% to 100%)

Max Speed Set* 0-100% 100% The maximum output control limit for the

MUA VFD or damper. Must be set to a value
that ensures proper design full flow CFM.
(Adjustable from 0% to 100%)

Tempering Set* 0-100% 66% Minimum run percentage for the MUA when

heating or cooling is being used.

Tempering Status On / Off Off Displays whether the MUA is heating or cooling

Fault Menu (No Settings)

Faults

System Fault No/Yes No Indicates that there is a fault due to the

following:

Fire No/Yes No Status of contact input from fire alarm system.

Closed contact allows the fan to run.

Temp Fail No/Yes No Indicates that one of the temperature sensors

used to control the hood exhaust has failed.

Pressure Fail No/Yes No Indicates that the pressure sensor has failed.

Exh VFD Fault No/Yes No Status of exhaust fan VFD(s) fault contacts.

Open if failed.

MUA VFD Fault No/Yes No Status of MUA fan VFD(s) fault contacts. Open

if failed.

Exhaust

Exhaust Fan Speed*

EF1 Speed 0-100% - Indicates the speed at which EF1 is running
EF2 Speed 0-100% - Indicates the speed at which EF2 is running
EF3 Speed 0-100% - Indicates the speed at which EF3 is running
EF4 Speed 0-100% - Indicates the speed at which EF4 is running
EF5 Speed 0-100% - Indicates the speed at which EF5 is running

EF Min. Fan Speed*

EF1 Min 0-100% 50% Indicates the minimum fan speed to achieve

positive hood capture for EF1

EF2 Min 0-100% 50% Indicates the minimum fan speed to achieve

positive hood capture for EF2

EF3 Min 0-100% 50% Indicates the minimum fan speed to achieve

positive hood capture for EF3

EF4 Min 0-100% 50% Indicates the minimum fan speed to achieve

positive hood capture for EF4

EF5 Min 0-100% 50% Indicates the minimum fan speed to achieve

positive hood capture for EF5

* To see values, you need to log in.

®

Vari-Flow Air Management System

11

Exhaust - continued

EF Max Fan Speed

EF1 Max

EF2 Max

EF3 Max

EF4 Max

EF5 Max

Exhaust Temperature Set Points*

EF1 Low Temp °F 90°F
EF1 High Temp °F 115°F

EF2 Low Temp °F 90°F
EF2 High Temp °F 115°F

EF3 Low Temp °F 90°F
EF3 High Temp °F 115°F

EF4 Low Temp °F 90°F
EF4 High Temp °F 115°F

EF5 Low Temp °F 90°F
EF5 High Temp °F 115°F

Exhaust Mode

Exhaust in Fire No / Yes Yes Indicates the exhaust fan(s) will run in case of fire

Fans Full Speed No / Yes - Indicates the operator overrode the exhaust fan to full

100% Timer Minutes 15 min The set time the fan 100% override runs for.

Time Left Minutes - Indicates the time remaining for the full speed

Exhaust Fans*

Fan1 Connected No / Yes Yes Indicates if EF1 is connected

Fan2 Connected No / Yes No Indicates if EF2 is connected

Fan3 Connected No / Yes No Indicates if EF3 is connected

Fan4 Connected No / Yes No Indicates if EF4 is connected

Fan5 Connected No / Yes No Indicates if EF5 is connected

Descriptors/Value Default

Use

0-100% 100% Indicates the maximum fan speed to meet design

airflow requirements for EF1

0-100% 100% Indicates the maximum fan speed to meet design

airflow requirements for EF2

0-100% 100% Indicates the maximum fan speed to meet design

airflow requirements for EF3

0-100% 100% Indicates the maximum fan speed to meet design

airflow requirements for EF4

0-100% 100% Indicates the maximum fan speed to meet design

airflow requirements for EF5

The temperature at which EF1 runs at the minimum speed.
The temperature at which EF1 runs at the maximum speed.

The temperature at which EF2 runs at the minimum speed.
The temperature at which EF2 runs at the maximum speed.

The temperature at which EF3 runs at the minimum speed.
The temperature at which EF3 runs at the maximum speed.

The temperature at which EF4 runs at the minimum speed.
The temperature at which EF4 runs at the maximum speed.

The temperature at which EF5 runs at the minimum speed.
The temperature at which EF5 runs at the maximum speed.

speed operation

override

Grease Grabber H2O with Vari-Flow Settings

GGH2O/
Vari-Flow Settings

GGH2O Force Fan Off No / Yes No If yes the exhaust fan(s) are forced off to prevent

GGH2O Fan Dry
Active

GGH2O Fan Mode

Descriptors/Value Default Use

water from being drawn into the exhaust duct during
the wash cycle. The fan button on the keypad is
disabled.

No / Yes No If yes, the exhaust fan(s) is(are) forced on to dry the

filters following the wash cycle.

0-10 VDC - 0 V-Fan(s) Auto

0-10 VDC - 5 V-Fan(s) Off

0-10 VDC - 10 V-Fan(s) Dry

* To see values, you need to log in.

Vari-Flow Air Management System

12

®

SEQUENCE OF OPERATION – VARI-FLOW

p

(

)

System Start Stop

Hood Switch

OFF

Temperature

Interlock

YES

DDC

Temperature

Control

Enabled

Compare Highest

Temperature

Readings with Hood

Operating Temp

Set

oint

Hood VFD Speed

Set According to

Temperature

NO

ON

Hood Full Speed

DDC

Temperature

Control
Enabled

Hood VFD Set to

Full Speed

15 minute timer /

Full Speed Cancel

Full Speed

Cancel

Return to System

Start/Stop

FAULT & FAILURE OPERATION

MUA/SF/OA Damper Pressure Control

Hood Running

Signal Received

Pressure or

Tracking?

TRAK PRES

MUA/SF VFD Speed

Set by Proportional

Tracking

OA Damper
Position Set

(open/closed)

NO

YES

Compare Space Static

Pressure Reading

with Space

Pressure Setpoint

+.05”WC, adjustable

MUA/SF

VFD Speed Set

According to

Pressure

Start & Run

Hood VFD

MUA/SF VFD

Interlock

Temp
Sensor
Failure

FIRE MODE OPERATION

START FAN

Fan(s) will run

System Failure

Light On

DDC

Temperature

Control
Enabled

Hood VFD Set to

Full Speed

Exhaust off in Fire Exhaust on in Fire

Exhaust VFD

Fault

MUA/SF

VFD Fault

START FAN

Fan(s) will run

Space Pressure

Sensor Failure

(Beyond -

.25/+.25”WC

Hood VFD Set to

Full Speed

System Failure

Set MUA to run

on Tracking

)

Light On

NO

FIRE?

YES

Exhaust

Fan(s)

remain ON

®

Supply Fan(s)

will turn OFF

Fan(s) will
turn OFF

FIRE?

YES

Exhaust

NO

Supply

Fan(s) will

turn OFF

Vari-Flow Air Management System

13

Daily Operations of Vari-Flow System

The following section details the buttons on the
Vari-Flow keypad and their function as it relates to the
daily operation of the system.

Hood Lights - Momentarily pressing the ‘Hood
Lights’ button will turn on all lights for the respective
hood(s) attached to the system. A green LED light will
illuminate under the Hood Lights button indicating
power to the lights. Pressing the ‘Hood Lights’ button
again will turn off the lights for the respective hood(s).
The green LED light will no longer be illuminated.

Fan On/Off- Momentarily pressing the ‘Fan On/Off’
button will turn on the fan(s) (exhaust and supply
where applicable) for the respective hood(s) attached
to the system. A green LED light will illuminate under
the Fans On/Off button indicating power to the fans.
The fans will start at a minimum speed and vary
automatically based on heat load generated by the
appliances.

Fan 100% - Momentarily pressing the ‘Fan 100%’
button while the fans are operating will send the fan
speed for the entire system to 100% for 15 minutes
(adjustable) or until the Fan 100% button is pressed
again. Pressing the Fan 100% button again will take
the fans out of 100% operation and return them to
standard operating conditions.

NOTE

When Vari-Flow is operating in temperature interlock
mode the fan 100% LED will flash. During this time
the fans may be manually turned on by pressing the
on/off button.

NOTE

In the event of a potential system fault, the display
will turn on an event message describing the fault.
This info can be used in servicing the fault.

System Optimization

Low Temperature Set Point (90˚F default)

Record the kitchen ambient temperature ________

Set the low temperature set point 5˚F above the
ambient kitchen temperature

Setting the Low Temperature Set Point

• Select the Exhaust menu on the PLC and scroll to

the right by pressing the right arrow button.

• Press return and scroll down using the down arrow

key until “EF1 LowTemp” is displayed.

• Press return and adjust the low temperature set

point by pressing the up or down arrow button.

• Once desired low temperature set point is reached,

press the return button.

• Press the escape (ESC) button to return to the

desired menu.

High Temperature Set Point (115˚F default)

• Turn the fans on by pressing the Fan On/Off
button.

• Turn on all cooking appliances and allow them to

reach normal cooking temperatures.

• Record the temperature in the hood by looking at

the “Temp Sensors” menu on the PLC. ________

• Set the high temperature set point 5˚F below the
previous recorded temperature.

Setting the High Temperature Set Point (refer to

page 8 for keypad functionality)

• Select the Exhaust menu on the PLC and scroll to

the right by pressing the right arrow button until the
“Exh Temp Setpoints” is reached.

• Press return and scroll down using the down arrow

button until “EF1 HighTemp” is selected.

• Press return and adjust the high temperature set

point by pressing the up or down arrow button.

• Once desired high temperature set point is reached,

press the return button.

• Press the escape (ESC) button to return to the

desired menu.

LED Display Guide (LED’s on face of Programmable Logic Controller U1)

Indicator Operation Detail

Power Power When LED is lit the controller is powered on.

Alarm Alarm When LED is lit the system is experiencing a fault.

1 Exhaust Fan Run When LED is lit the controller is commanding the exhaust fans to run.

2 Supply Fan Run When LED is lit the controller is commanding the supply fans to run.

3 Supply Fan Heat/Cool When LED is lit the supply fan is operating in heating or cooling.

4 Pressure Sensor Fault When LED is lit the pressure sensor is experiencing a fault.

5 Fire When LED is lit the system is operating in fire mode.

6 Temperature Sensor Fault When LED is lit the controller is not receiving a correct reading from

the temperature sensor.

7 Exhaust VFD Fault When LED is lit the exhaust VFD is experiencing a fault.

8 Supply Fan VFD When LED is lit the supply VFD is experiencing a fault.

Vari-Flow Air Management System

14

®

Troubleshooting Guide

Issue Possible Cause Recommended Solution

Smoke spilling out of hood
at 100% operation

Smoke spilling out when
hood running at lowest
speed

Fans do not turn up to
maximum speed

Fans do not turn down to
minimum speed

Exhaust fan on and supply
fan off

Fans rotate in wrong
direction

100% override does not
increase exhaust

Fan switch is on, but fans do
not turn on

Hood lights LED on, but no
lights come on

Fan 100% LED is flashing

Fans do not turn on
automatically

Pressure Sensor Fault

Fire

Temperature Sensor Fault

Exhaust VFD Fault

Supply VFD Fault

Max fan speed has been
scaled down from 100%

Improper hood design

Fan minimum speed set
too low

Improper hood design

Dirty temperature sensor Clean grease from temperature sensor

High temperature set
too high

Dirty temperature sensor Clean grease from temperature sensor

Low temperature set
too low

Broken supply fan belt Replace fan belt

Fire mode Check fire contact connection

VFD output wiring incorrect

Exhaust already at 100% Proper Operation

Bad wiring connection

Broken fan belt Replace fan belt

VFD fault Check VFD for faults

Bad wiring connection

Light bulbs are burned out Replace hood light bulbs

Bad wiring connection

Vari-Flow is operating
in temperature interlock
mode

Temperature Interlock
Enabled set to no

Interlock set point too high

Kinked hose Remove kink or replace hose

Controlled space not
holding pressure

Fire system microswitch is
in the fire position

Dirty/burned sensor Clean/replace sensor

Incorrect programming Check the temperature sensor settings

VFD over current Check fan rotation

Fan FLA not set in the VFD
parameters

VFD over current Check fan rotation

Fan FLA not set in the VFD
parameters

Increase exhaust fan maximum speed to 100%.

Check hood overhang, cross drafts, or proper
make up air

Increase exhaust fan minimum speeds

Check hood overhang, cross drafts and proper
make up air

Decrease the high temperature set point
(115°F default)

Increase the low temperature set point
(90°F default)

Switch any two leads on the hood side of the
VFD to the fan motor

If fan 100% LED does not light check keypad
connection

If fan on/off LED does not light check keypad
connection

If hood lights LED is lit check wiring connection to
hood lights

Press the Fan On button to manually turn on the
fans

Turn the Temperature Interlock Enabled to yes

Adjust the temperature interlock set point
(90°F default)

Adjust the static pressure set point

Check the fire suppression microswitch
connections

Check the VFD overload settings (PAR E2-01)

Check the VFD overload settings (PAR E2-01)

®

Vari-Flow Air Management System

15

Warranty

Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from
the shipment date. Any units or parts which prove defective during the warranty period will be replaced at our option
when returned to our factory, transportation prepaid. Motors are warranted by the motor manufacturer for a period of
one year. Should motors furnished by Greenheck prove defective during this period, they should be returned to the
nearest authorized motor service station. Greenheck will not be responsible for any removal or installation costs.

As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications
without notice.

AMCA Publication 410-96, Safety Practices for Users and Installers of Industrial and Commercial Fans, provides additional
safety information. This publication can be obtained from AMCA International, Inc. at www.amca.org.

®

Phone: [phone] • Fax: [phone] • E-mail: [e-mail] • Website: www.greenheck.com

472966 • Vari-Flow Air Management System, Rev. 2, September 2010 Copyright 2010 © Greenheck Fan Corporation

16