Greenheck vari-green Installation, Operation & Maintenance Manual

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Document 473681

Vari-Green® Motor and Controls

Installation, Operation and Maintenance Manual

Please read and save these instructions for future reference. 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 could result in personal injury and/or property damage!

Vari-Green® Motor

The Vari-Green Motor is an electronically commutated (EC) motor that uses AC input power and internally converts it to a DC power supply which provides an 80% turndown capability and increased energy savings.

NOTE

When using a clamp meter to measure input amp draw, the meter must be capable of reading a non-linear current. Erroneous readings will occur otherwise.

Table of Contents

Reference part number listed in chart to locate speciﬁc motor information page number.

HP Voltage

1/6 115 300-1725 TENV

1/4 115 300-1725 ODP

1/4

208-230

1/2 115 300-1725 ODP

1/2

208-230

1/2 115 300-2500 ODP

3/4 115 300-1725 ODP

3/4

208-230

3/4 115 300-2200 ODP

1 115 300-1725 ODP 12.4 Pot/0-10V

208-230

2 208-230 300 - 1725 TEFC 12.0 Pot/0-10V 310420 4

* Actual maximum RPM may vary. See RPM column in chart on

pg.10 for speciﬁc motor and fan combinations.

* RPM Range

115/

300-1725 ODP 3.3/1.8 Pot/0-10V 310175 6

115/

300-1725 ODP 6.8/3.5 Pot/0-10V 310176 6

115/

300-1725 ODP 9.0/4.9 Pot/0-10V 310177 6

115/

300-1725 ODP 11.4/6.3 Pot/0-10V 310178 6

115/

300-1725 TEFC 12.0/6.0 Pot/0-10V 311156 4

Encl. FLA

Control Method

3.1 0-10V Only 311352 2

3.1 Pot Only 311353 2

3.4 Pot/0-10V

3.9 0-10V Only 310107 2

3.9 Pot Only 310108 2

3.7 Pot/0-10V 311377 3

6.2 0-10V Only 309025 2

6.2 Pot Only 309028 2

6.7 Pot/0-10V 311812 3

6.5 0-10V Only 310307 2

6.5 Pot Only 310476 2

6.5 Pot/0-10V 312360 3

10.1 0-10V Only 309026 2

10.1 Pot Only 309029 2

10.6 Pot/0-10V

11.3 0-10V Only 310306 2

11.3 Pot Only 310475 2

11.3 Pot/0-10V 312361 3

Motor

Part No.

311731 3

312359 3

311388 3

312619 3

310359 3

312362 3

Pg.

Troubleshooting ...........................7-9

Maximum RPM Table ....................... 10

Vari-Green Motor

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Features, Operation, Wiring and Troubleshooting

Features

Soft start – All motors feature soft-start technology which eliminates inrush current at startup. The motors will reliably start at any speed setting.

Overload protection – If the motor becomes overloaded, it will automatically reduce its speed until it is no longer overloaded. This means that the motor will never operate in the “service factor” which is possible with many AC motors.

Locked rotor protection – If the motor ever encounters a locked-rotor scenario, the motor will automatically shut itself down. It will try to restart up to 3 times, and if after the 3rd time the motor will still not rotate, the motor will not attempt to start again until power is cycled.

Thermal protection – The motors have a one-shot fuse thermal protector. This is meant to protect the motor from a severe temperature rise. With the motor controller’s ability to software limit the speed, the fuse is used as a last resort to prevent a ﬁre.

RPM measurement – The motors have a small shaft extension on the end of the motor to measure motor RPM with either a contact or optical tachometer.

Operation and Wiring

- Potentiometer Dial Only

Part Numbers Covered in this Section

309028 309029 310108 310475 310476 311353

These motors feature a potentiometer dial on the motor for speed adjustment. A small screwdriver can be used to make the speed adjustment. To increase the speed, rotate the dial clockwise. To decrease the speed, rotate the dial counter clockwise.

The motor is pre-wired at the factory and cannot be changed inside the motor. Connect single-phase power at the voltage listed on the nameplate.

These motors cannot be converted to receive a remote control signal – a different motor is needed. Please consult the factory.

Operation and Wiring

- 0-10V Input Only

Part Numbers Covered in this Section

309025 309026 310107 310306 310307 311352

These motors will accept a 0-10 VDC control signal for speed control. From 0-1.9V, the motor will be off, and will operate in the 2-10V range. 24 VAC/DC power is also required for operation. The motor will consume

0.7VA at 24 VAC or 25mA at 24 VDC. A factory mounted transformer is available to supply this voltage. See Fig. 1

The motor is pre-wired at the factory and cannot be changed inside the motor. Connect single-phase power at the voltage listed on the nameplate, along with the 0-10 VDC and 24V signal for speed control.

NOTE: The motor will not operate without the proper control voltages.

Transformer Assembly

Fig. 1

0-10 VDC External connection with factory mounted transformer

Vari-Green Motor

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Operation and Wiring

- Potentiometer Dial and 0-10V Input

Part Numbers Covered in this Section

310359 311731 311377 311388 311812 312359 312360 312361 312362 312619

These motors have both a potentiometer dial on the motor for speed adjustment AND have the ability to accept a 0-10 VDC signal for remote speed control. NOTE: The presence or absence of the 24V power determines whether the motor uses the dial or the 0-10VDC signal for speed reference.

There is a 4 second delay between the application of power and the motor starting.

The motor is pre-wired at the factory and cannot be changed inside the motor. Connect single-phase power at the voltage listed on the nameplate. If remote control is desired, connect the 0-10 VDC and 24V signal for remote speed control.

Dial on motor – A small screwdriver can be used to make the speed adjustment. To increase the speed, rotate the dial clockwise. To decrease the speed, rotate the dial counter clockwise. There is no need to connect the control wires.

0-10 VDC signal – The dial on the motor must be rotated fully clockwise to achieve the full speed range. If this is not done, the dial will act as a maximum speed limiter.

From 0-1.9V, the motor will be off, and will operate in the 2-10V range. 24 VAC/DC power is also required for operation. The motor will consume 0.7VA at 24 VAC or 25mA at 24 VDC. A factory mounted transformer is available to supply this voltage. See Fig. 1

A low voltage wiring harness is needed to supply the 0-10V signal to the motor. This harness is available from the factory if conversion is necessary.

Type Use with Motor 18 in. long 36 in. long

3-pin 311731, 310359 384431 384432

312359, 311377,

9-pin

The 9-pin connector on the motor contains 6 wires. The red, black and white wires are used for the external control signal and the other three are used for factory initialization and programing.

311812, 311388, 312360, 312361,

312362, 312619

384840 384805

NOTE

Factory Mounted Transformer (Fig. 1)

A factory mounted transformer is available to supply 24 VDC power to the motor when the 0-10V signal is by others. This transformer has the capability to power a remote device if desired. The power available to a remote device is 400mA at 24 VDC. If the remote device is powered by a different source, connect the analog output to the 0-10V and COM terminals of the transformer. This will pass the signal through to the motor.

WARNING

Do not connect an external 24V transformer to the control terminal labeled 24V. If the external device providing the 0-10V signal is powered elsewhere, this terminal can remain unused.

0-10V Analog input connection

Red + 0-10 VDC

White Common*

Black +24 VAC/DC

* Common is shared between both 24V power

and 0-10V signal.

The impedance of 0-10V circuit is 12KΩ

Troubleshooting

Motor does not operate

1. Check all wiring connections to ensure they are correct and secure.

2. Verify that all voltages are present at the motor, including 24V and 0-10 VDC, if applicable.

3. Make sure that the fan wheel will rotate freely and there are no foreign objects in the wheel. If fan wheel does not rotate freely, disconnect power from the motor and adjust the wheel or housing until the wheel can freely rotate. Apply power and the motor should restart.

4. If motor has both the dial on the motor and 0-10VDC control option, control wiring issues can be tested by disconnecting the control wires from the motor. The motor should then operate using the dial on the motor for speed control.

Motor will not reach maximum speed

1. Make sure dial is rotated full clockwise, if applicable.

2. Make sure motor is receiving 10 VDC, if applicable.

3. There are some motor/fan combinations where the motor may not reach nameplate RPM. See Max RPM table on page 10 for the maximum motor speed for your application.

Vari-Green Motor

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Part Numbers Covered in this Section

310420 311156

0-10V Analog input connection

Red + 0-10 VDC

White Ground

Features

Speed control These motors can be controlled by either a dial on the motor or a 0-10 VDC signal for remote control.

Soft start – All motors feature soft-start technology which eliminates inrush current at start-up. The motors will reliably start at any speed setting. There will be up to a 30 second delay between the application of power and the motor starting.

Overload protection – If the motor becomes overloaded, it will automatically shut itself down. The maximum programed motor speeds have been selected to prevent this from happening in normal operation.

Locked rotor protection – If the motor encounters a locked-rotor scenario, it will automatically shut itself down. It will try to restart up to 3 times, and if after the 3rd time the motor will still not rotate, the motor will not attempt to start again until power is cycled.

Thermal protection – The motors have an automatic reset thermal protector. This is meant to protect the motor from a severe temperature rise.

RPM measurement – The motor RPM can be measured by removing the cooling fan cover and using a contact or optical tachometer. Be sure to replace the cooling fan cover when ﬁnished.

Reversible rotation – The motor direction has been pre-set at the factory for the rotation of the fan but can be reversed if necessary.

Operation and Wiring

These motors can be controlled by either a dial on the motor or a 0-10 VDC signal for remote control. The motor will be supplied from the factory with the correct accessory depending on what was ordered.

Dial on Motor - Turn the dial with your ﬁngers to adjust. To increase the speed, rotate the dial clockwise. To decrease the speed, rotate the dial counter clockwise. Turning the dial full CCW will turn the motor off.

0-10 VDC Signal - From 0-1.9V, the motor will be off, and will operate in the 2-10V range. This motor does not require 24V power for operation.

Wiring

1. All high and low voltage wiring connections are made inside the motor control box at the factory. Normally, there is no reason to enter the control box of the motor. If there is a need to enter the control box, disconnect power and wait at least ﬁve minutes to allow the capacitors to discharge.

2. The motors are factory wired for the ordered voltage. If the factory wired voltage does not match the desired voltage, the voltage can be changed, with exception of the 2HP motor (310420), which is 208-240V only.

115V: Connect 115 VAC to L1, connect Neutral to N. The L2 terminal remains empty. Connect ground to grounding stud.

115V Connection inside control box

208-240V - Connect Line voltage to L1 and L2. The N terminal remains empty. Connect the ground to the grounding stud.

Vari-Green Motor

208-240V Connection inside control box

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Dial on motor - the dial is factory-wired into the low voltage terminal block inside the control box. The wires are connected

RED WHITE BLACK

YELLOW YELLOW

as shown.

Dial on motor connection inside control box

0-10 VDC Signal - a two-wire pigtail is factory-wired into the low voltage terminal block. The wires are connected as shown.

0-10 VDC Signal connection inside control box

RED

WHITE

YELLOW YELLOW

If the motor needs to be tested before the 0-10 VDC signal is available, a jumper can be placed between terminals 1 and 2. This will force the motor to run at full speed.

Troubleshooting

These motors have a diagnostic red LED on the circuit board inside the control box, or on the exterior of the control box, that will be solid (not ﬂashing) when power is applied to the motor and the motor is operating normally. The LED may be solid even if the motor is not spinning, such as when power is applied but the motor may be commanded to be off with a 0-1.9V VDC signal.

1. If external LED is not present, to view the status of the LED the control box cover must be removed while power is applied to the motor. If the control box cover is removed while power is applied, extreme care must be taken not to touch any of the components inside the box.

a. If a fault occurs, the LED will blink a speciﬁc

number of times to identify the fault that has occurred. The fault indications are as follows:

Number of Blinks Indicated Fault

2 Overcurrent

3 Overvoltage

4 Undervoltage

5 Communication Error

6 Sync Loss

7 Spin Fault

8 Motor overload

9 Motor Over Temperature

Motor Rotation

To reverse the rotation of the motor, swap any two of the red, black and blue wires connecting the control board to the motor at terminals T1, T2 and T3. Note that motor warranty is void if motor is rotating in the wrong direction. See fan instruction manual for correct rotation direction.

Rotation selection wires inside control box

3. When the LED is blinking, it will consecutively blink from 2 to 9 times, followed by a pause, and repeat the blink sequence. It is best to count the number of ﬂashes 2 or 3 times to ensure accuracy.

4. Under most fault conditions the motor will automatically restart. If a motor overload fault occurs more then 10 times in one hour, the motor will shut down and require a power cycle to reset.

5. If the fault persists, consult the factory.

Motor does not operate

1. Verify the motor is wired for the correct voltage.

2. Verify that the dial on the motor is properly connected to the control board - or - verify that the 0-10 VDC wires are properly connected to the control board.

3. Verify that the Status LED is solid red.

4. Verify that a jumper is in place between terminals 9 and 10. The motor will not run without this jumper in place.

5. Verify that the two yellow wires coming from the motor are in place on terminals 5 and 6.

Vari-Green Motor

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Part Numbers Covered in this Section

310175 310176 310177 310178

Features

Speed control These motors can be controlled by either the dial on the motor or a 0-10 VDC signal for remote control.

Soft start – All motors feature soft-start technology which eliminates inrush current at start-up. The motors will reliably start at any speed setting. There will be a 4 second delay between the application of power and the motor starting.

Overload protection – If the motor becomes overloaded, it will automatically reduce its speed until it is no longer overloaded. This prevents the motor from operating in the "service factor" should the motor be misapplied.

Thermal protection – The motors have electronic thermal protection. If the motor temperature exceeds its limits, it will slow itself down until the temperatures have dropped.

0-10 VDC Signal - From 0-1.9V, the motor will be off, and will operate within the 2-10V range. This motor does not require 24V power for operation. For 0-10V operation, a 16-pin connector with two wires connected to pins 8 and 16 is required. (18 in. #384822 • 36 in. #384821)



Wiring

A power cord with a 5-pin connector is required and is shipped with the motor. A different cord assembly is needed depending on the desired voltage:

115V - 18 in. #384824 • 36 in. #384823

Operation and Wiring

These motors can be controlled by either the dial on the motor or a 0-10 VDC signal for remote control. The motor will be supplied from the factory with the correct accessory depending on what control option was ordered.

Dial on Motor - Turn the dial with your ﬁngers to adjust. To increase the speed, rotate the dial clockwise. To decrease the speed, rotate the dial counter-clockwise. Turning the dial full CCW will turn the motor off. A 16-pin connector with two jumper wires must be installed for the dial to function. (p/n 384962) See image below.



208-230V - 18 in. #384826 • 36 in. #384825

Vari-Green Motor

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Controls: Operation, Wiring and Troubleshooting

Remote Dial and 2-Speed Control

Other Vari-Green® controls, such as the Constant Pressure and Air Quality families of controls, have their own manual that ship with the controller. They can also be found on Greenheck.com. See table on page 9 for document numbers.

Remote Dial Assembly

Remote Dial

Installation Overview: The remote dial is provided with the fan, shipped loose for remote installation. It also includes a factory mounted 24 VDC transformer.

1. Disconnect power to the fan.

2. Identify where the remote dial will be mounted.

3. Mount a standard single-gang 2x4 junction box.

4. Run a 3-wire control cable from the remote dial to the fan motor compartment. The maximum distance from the fan to the remote dial is 100 feet. If a greater distance is required, signal loss may occur and cause the fan to operate erratically.

5. Connect control cable to transformer mounted inside fan motor compartment. Connect control cable to remote dial.

6. Secure remote dial to 2x4 junction box.

CAUTION

Even though the motor may not be operating, high voltage power may still be present at the motor. Make sure to disconnect power to the fan before servicing.

Troubleshooting - Remote Dial

Remote Dial does not adjust motor RPM

1. Check voltage to ensure the motor and transformer are receiving the correct line voltage.

2. Check voltage at the remote dial. 24 VDC should be present across the 24V and COM terminals. 0-10VDC should be present across the 0-10V and COM terminals.

3. Verify all of the connections at the transformer and make certain that they are secure.

Terminals Desired Voltage

24V-COM 24 VDC Nominal

0-10V-COM

0-10 VDC

(varies with dial position)

Vari-Green Motor

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Two Speed Assembly

Two Speed

Installation Overview: The two speed control is factory mounted to the fan and may be set to provide any two speeds the application requires. It also includes a 24 VAC transformer which has a dual voltage primary (115/230V), selectable via a switch on the housing near the power cable. The voltage will be factory set to match the motor voltage.

1. A green LED will be illuminated when the 2-speed control is powered.

2. There are two methods of toggling between speed A and speed B:

a. Dry contact input - this utilizes an external

switching device such as a relay or SPDT switch to toggle between the two speeds.

• Connect terminal “A” to “COM” for speed A.

• Connect terminal “B” to “COM” for speed B.

If no contact is made between either terminal the motor will be off.

b. AC Digital input - this input allows an AC voltage

signal to be fed directly into the 2-speed control to change speeds.

• Send 115-230V AC to L1 OR L2 for speed B.

• Send 115-230V AC to L1 AND L2 for speed A.

If no voltage is applied to either terminal, the motor will be off.

c. DO NOT CONNECT BOTH DRY CONTACT AND

DIGITAL INPUTS SIMULTANEOUSLY.

3. To test fan operation before the external control devices are installed, a jumper wire can be connected between the COM and A or B terminal on the dry contact input for fan operation.

Troubleshooting - Two Speed

1. Check all wiring connections to ensure they are correct and secure.

2. Verify AC line voltage is present at the motor and 2-speed control.

3. Verify 24V AC is present at the 24V and COM terminals of the "Motor" terminal block.

4. Measure DC voltage between the 0-10V and COM terminals of the "Motor" terminal block. This voltage should match the dial position of the active dial.

a. If using dry contact input - ensure contact closure

is connecting the proper terminals.

b. If using AC digital input - disconnect connector

from 2-speed control and measure voltage between L1 and Neutral or L2 and Neutral.

Multiple motors on one control

See the table below for the recommended number of motors to be driven from one controller. Note that the controllers do not have the ability to distinguish between more than one motor, therefore all motors will receive the same control voltage.

Controls Maximum Motor Quantity

Remote Dial 4

2 Speed 6

Constant Pressure 4

Temperature/Humidity 2

VOC 2

Vari-Green Motor

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Maintenance

Vari-Green® motors use brushless technology with sealed bearings. No routine maintenance is required other than keeping any debris from accumulating on the motor and controls.

Other Vari-Green® Control Instruction Manuals

Description Document Number

Indoor Air Quality - VOC 475407

Indoor Air Quality - Temperature/Humidity

Constant Pressure Control 474766

475573

Notes:

Vari-Green Motor

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Maximum RPM Table

This table will show the available motor and fan combinations with the correlating maximum motor RPM for each combination.

G Max RPM Motor HP

60-75 1725 1/6

80-95 1725 1/6

97-99 1725 1/4

103 1725 1/4

103HP

123

1725 1/4

2500 1/2

1200 1/4

1725 1/2

1150 1/4

133

1550 1/2

1725 3/4

900 1/4

143

1200 1/2

1300 3/4

1725 1

1500 1/4

143HP

1725 1/2

2200 3/4

750 3/4

163

1200 1

1725 2

900 3/4

183

1000 1

1400 2

SQ Max RPM Motor HP

60-75 1725 1/6

80-95 1725 1/6

100 1725 1/4

120 1725 1/2

130 1725 3/4

140

1500 3/4

1725 1

1140 3/4

160

1300 1

1725 2

CUE/CW Max RPM Motor HP

60-75 1725 1/6

80-95 1725 1/6

99 1725 1/4

101 1725 1/4

101HP

121

1725 1/4

2500 1/2

1400 1/4

1725 1/2

1200 1/4

131

1450 1/2

1725 3/4

1000 1/4

141

1300 1/2

1550 3/4

1725 1

1450 1/4

141HP

1725 1/2

2200 3/4

1000 1/2

161

1200 3/4

1300 1

1725 2

1300 1/2

161HP

1650 3/4

1725 1

875 3/4

180

1000 1

1400 2

LD/LDP Max RPM Motor HP

80-95 1725 1/6

100 1725 1/4

120 1725 1/2

SWD Max RPM Motor HP

1725 1/4

2500 1/2

1725 1/4

2500 1/2

1725 1/4

2200 3/4

1200 1/4

1550 1/2

1725 3/4

1150 1/2

1400 3/4

1725 1

900 3/4

1300 2

1725 2

850 3/4

950 1

1300 2

SFD Max RPM Motor HP

6 1725 1/4

7.5 1725 1/2

SE1/SS1 Max RPM Motor HP

8-440 1725 1/6

10-440 1725 1/6

12-426 1725 1/4

12-432 1725 1/4

12-436 1725 1/4

14-432 1725 1/4

14-436 1725 1/2

14-440 1725 1/2

16-421 1725 1/2

16-426 1725 1/2

16-428 1725 3/4

16-436 1725 3/4

18-424 1725 3/4

18-429 1725 3/4

20-420 1725 1

Vari-Green Motor

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Vari-Green Motor

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Our Commitment

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

Speciﬁc Greenheck product warranties can be located on greenheck.com within the product area tabs and listed in the Library under Warranties.

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: (715) 359-6171 • Fax: (715) 355-2399 • E-mail: gfcinfo@greenheck.com • Website: www.greenheck.com