Greenheck Vektor Laboratory Exhaust User Manual

Document 476072

Vektor

with Variable Geometry Nozzle (VGN) Technology

Laboratory Exhaust

Electrical Controls Information

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!

Table of Contents

General Safety Information ......................1

Receiving, Handling and Storage .................2

VFD Controller Nozzle Controller

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 Electrical 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 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) may be hot enough to cause pain or injury. Allow motor to cool before servicing.

Component Checklist - Electrical ...............2

System Components ...........................3

Wiring Installation .............................3

Fan Operation - Single Fan

Set Point and Minimum Variables ...............4

Defined Modes .............................4

VGN Technology Control Flow Chart ............5

Fan Operation - Multiple Fans, No Staging

Set Point and Minimum Variables ...............6

Defined Modes ........................... 6-7

VGN Technology Control Flow Chart ............8

Fan Operation - Multiple Fans, With Staging

Set Point and Minimum Variables ...............9

Defined Modes ............................10

VGN Technology Control Flow Chart ...........11

Factory-Supplied Variable Frequency Drive

System Diagram .............................12

Wiring Diagram ..............................13

Communication BACnet® and LonWorks® Protocol . 14

Start-Up Procedure - Electrical Controls ..........15

System Test and Balance for VGN ...............16

Nozzle Velocity Adjustment .....................16

Customer-Supplied Variable Frequency Drive

System Diagram .............................18

Wiring Diagram ..............................19

VGN Nozzle Controller Intro. and Tutorial ....... 20-22

Communication ..............................23

Start-Up Procedure - Electrical Controls ..........24

System Test and Balance for VGN ...............25

Nozzle Velocity Adjustment .....................25

Troubleshooting ..............................26

Maintenance ................................27

Electrical Replacement Parts ...................27

Our Commitment .............................28

VGN Technology

General Electrical Controls Information

Receiving

Upon receiving the product, check to ensure all items are accounted for by referencing the delivery receipt or packing list. Inspect each crate or carton for shipping damage before accepting delivery. Alert the carrier of any damage detected. The customer will make a notation of damage (or shortage of items) on the delivery receipt and all copies of the bill of lading which is countersigned by the delivering carrier. If damaged, immediately contact your Greenheck Representative. Any physical damage to the unit after acceptance is not the responsibility of Greenheck Fan Corporation.

Component Checklist - Electrical

Check off the following system components to verify all components are received.

 ABB Eclipse Variable Frequency Drive (VFD) with

bypass mode and internal wiring kit. (VGN with factory-supplied VFD)

 VGN nozzle controller

(VGN customer-supplied VFD)

 Transducer/terminal enclosure with Sure Aire™

pressure transducer and system terminals in NEMA3R enclosure

 24 volt VGN nozzle with modulating actuator

0/2-10 VDC with feedback

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.

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 eliminate 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.

Removed 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.

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

VGN Technology

General Electrical Controls Information

System Components

System Components (supplied by Greenheck)

Quantity Description

1 Pressure transducer with adjustable pressure

range and VDC signal

1 VFD with bypass mode and integrated controller

(VGN with factory-supplied VFD)

1 VGN nozzle controller.

(VGN, customer-supplied VFD)

1 to 4 Actuator motor(s) (nozzle)

24 volts, modulating VDC signal with feedback

Varies Actuator motor (bypass damper), if provided by

manufacturer

Varies Actuator motor (isolation damper) 24 volts,

open/close. Quantity will be zero if isolation

damper actuator is supplied by others or if gravity style isolation damper is used.

System Components (customer-supplied)

Quantity Description

Varies Wiring, conduit, miscellaneous ﬁttings

1 Building control system with required

communication wiring and shielding Varies Pressure transducer for duct pressure Varies Actuator motor (bypass damper) if provided by

others

1 Actuator motor (isolation damper), if provided

by others. Quantity will be zero if gravity style

isolation damper is used.

Varies 1/4 inch tubing. Connection from Sure-Aire

termination plate mounted on fan to mounting

location of transducer/terminal enclosure.

1 Fan motor VFD.

(VGN, customer-supplied VFD)

Wiring Installation

NOTE

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

NOTE

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

The following items are a list of requirements necessary to install the controls for the VGN Technology system.

1. Mount variable frequency drive in the desired location; indoors or outdoors. Maximum distance from fan is 100 feet (30.5 meters).

2. Mount transducer/terminal enclosure at fan or bypass air plenum (BAP).

3. Run main power wiring from building breaker panel to variable frequency drive. By others.

4. Run motor power wiring from service disconnect switch to variable frequency drive. Wire length to be less than 100 feet. By others.

5. Connect control wiring pigtail (by factory) from VGN nozzle actuator(s) to transducer/terminal enclosure. (See wiring diagram).

Optional: Connect wiring from isolation damper

actuator(s) to transducer/terminal enclosure. By others.

6. Run control wiring from transducer/terminal enclosure to variable frequency drive or nozzle controller terminal strip. Wire length to be less than 100 feet (See wiring diagram).

7a. Run communication cable from variable frequency

drive to Building Management System (BMS). See VFD manual for type and maximum length. By others. (VGN with factory-supplied VFD).

7b. Run VGN nozzle controller system wiring from main

control panel to Building Management System (BMS). By others. (Customer-supplied VFD).

8. Run nozzle actuator feedback control wire from transducer/terminal enclosure at the fan to BMS controls.

9. Install 1/4 inch pressure tubing (by others) from transducer/terminal enclosure to Sure-Aire connection plate on fan. By others.

10. Install BMS with duct pressure control system. By others.

11. For speciﬁc device installation reference the appropriate component cut sheet or IOM. Also reference the following system and wiring diagrams on pages 4 and 7 for more detail.

VGN Technology

General Electrical Controls Information

Fan Operation - Single Fan

Set point and minimum variables

1. System will maintain a minimum of 3000 fpm velocity (factory default) at the outlet of the fan, based on the airﬂow monitoring station. Building Management System (BMS) to monitor nozzle actuator feedback and keep fan speed above the minimum required set point to maintain velocity.

2. Fan to run at BMS deﬁned operation for speed and bypass mode. Mode reference will be determined by minimum fan speed and by minimum nozzle actuator feedback.

a. If the BMS speed is equal to the minimum speciﬁc

fan speed and nozzle feedback is minimum for a set time period (user-deﬁned) the BMS will begin to modulate the bypass damper open to assist with pressure control.

b. If the bypass damper is at full closed for a set time

period, the BMS will increase fan speed and the fan control will increase the nozzle area as required to assist with pressure control.

c. The PID sequence to be programmed at the BMS

for bypass damper operation. The BMS to provide fan enable and VFD speed reference.

Deﬁnition of typical operation modes:

Mode #1: Unoccupied. Deﬁned as no one inside the

lab(s), all lab hoods are closed.

1. Fan will operate at BMS required speed and nozzle will modulate as necessary to achieve the required velocity out the fan. BMS to monitor nozzle actuator feedback and keep fan speed above the minimum required to maintain velocity.

2. Sure-Aire will measure airﬂow of the fan. VFD or the nozzle controller will report this value to BMS.

3. Duct pressure control, by the BMS, will modulate bypass damper as required if system speed is equal to the minimum fan speed and nozzle actuator is at minimum for a time period.

4. VFD speed, duct pressure control and bypass damper operation is provided by the BMS system.

Mode #2: Occupied; no lab hoods being used.

Deﬁned as people entering the lab(s), no work being done at the hoods.

2. Sure-Aire will measure airﬂow of the fan. VFD or the nozzle controller will report this value to BMS.

3. Duct pressure control, by the BMS, will modulate bypass damper as required if system speed is equal to the minimum fan speed and nozzle actuator is at minimum for a time period (user-deﬁned).

4. VFD speed, duct pressure control and bypass damper operation is provided by the BMS system.

VGN Technology

Mode #3: Occupied; some or all lab hoods being used. Deﬁned as people in the lab(s), lab hood sashes

being used.

A. Sashes opening in the lab

1. Fan will operate at BMS required speed and nozzle will modulate as necessary to achieve the required velocity out the fan. Typical system response should be to increase fan speed and increase nozzle open area.

2. Sure-Aire will measure airﬂow of the fan. VFD or the nozzle controller will report this value to BMS.

3. VFD speed, duct pressure control and bypass damper operation is provided by the BMS system.

B. Sashes closing in the lab

1. Fan will operate at BMS required speed and nozzle will modulate as necessary to achieve the required velocity out the fan. Typical system response should be to decrease fan speed and decrease nozzle open area.

2. Sure-Aire will measure airﬂow of the fan. VFD or the nozzle controller will report this value to BMS.

3. Duct pressure control, by the BMS, will modulate bypass damper as required if system speed is equal to the minimum fan speed and nozzle actuator is at minimum for a time period (userdeﬁned).

4. VFD speed, duct pressure control and bypass damper operation is provided by the BMS system.

Mode #4: Fault mode. Deﬁned as safety mode; the system has an issue and needs to default to VFD bypass.

1. VFD failure detected, automatically or manually put

into VFD bypass if available, by operator or BMS.

2. Nozzle area to increase proportional to fan airﬂow

which will increase as fan speed is at maximum.

3. Sure-Aire will measure airﬂow of the fan. VFD or the

nozzle controller will report this value to BMS.

4. Duct pressure control will modulate bypass damper

as required if system is in alarm mode. Duct pressure control is provided and programmed by the BMS system.

5. System manually to be reset and placed back in VFD

auto mode.

General Electrical Controls Information

VGN Technology Control Flow Chart - Single Fan

Positive Pressure Fault

Negative Pressure Fault

Max. VFD

Monitor

Time

Above Setpoint

(more positive)

VFD

at Full Speed

Yes

BMS Control

Drive

Fault Bypass

Mode

Static

Pressure

Valve

Static

Pressure =

Setpoint

Static

Pressure

Value

Drive Fault

Yes

Below Setpoint

(more negative)

Feedback at

Minimum

Alarm

Nozzle

VFD at

Speed

Yes

Min. VFD

Monitor

Time

Fan at

Full Speed

Yes

Required

Nozzle Area

Increase

Fan Speed

Send to BMS

Controller

Time Period

Met?

Yes

Positive

Pressure

Alarm

Reset at

Fault CLR

Decrease

Fan Speed

Above Setpoint

(more positive)

Bypass

Damper

Bypass

Feedback

= Mimimum

VDC

Yes

Time Period

Met?

Yes

BMS Control

Bypass Damper

PID

Static

Pressure

Value

Static

Pressure =

Setpoint

Static

Pressure

Value

Reset by

BMS

Below Setpoint

(more negative)

Bypass

Damper

Yes

Feedback

= Maximum

Open

Bypass

VDC

Damper Position Monitor

NoNo

Time

Yes

Time Period

Met?

Reset by

BMS

No No

Time Period

Met?

Yes

Negative Pressure

Alarm

Reset at

Fault CLR

Send to BMS

Controller

VGN Technology

General Electrical Controls Information

Fan Operation - Multiple Fans, No Staging

Set point and minimum variables

1. System will maintain a minimum of 3000 fpm velocity (factory default) at the outlet of each fan, based on the airﬂow monitoring station. Building Management System (BMS) to monitor each fan nozzle actuator feedback and keep fan speed above the minimum required set point to maintain velocity.

2. Each fan to run at BMS deﬁned operation for fan on or off, and event timing, as required per system airﬂow requirements. BMS is also required to control fan speed for all fans. Bypass damper mode reference will be determined by the following scenario listed:

A. All fans in system running at minimum. Minimum

ﬂow condition.

a. BMS will control fan speed and monitor nozzle

feedback as required to maintain system set point.

b. Decreased ﬂow condition from minimum speed.

When the speed is equal to the minimum speciﬁc fan speed and nozzle feedback is at minimum for a set time period (user-deﬁned), the BMS will begin to modulate the bypass damper(s) open to assist with pressure control.

Increased ﬂow condition from minimum speed. If

the bypass damper(s) are at full closed for a set time period (user-deﬁned), the BMS will increase fan speed and the fan control will increase the nozzle area as required to assist with pressure control.

c. The PID sequence to be programmed at the BMS

for the bypass damper(s) operation. The BMS to provide fan enable and VFD speed reference.

B. Normal operation. Fan operation normal system

ﬂow.

a. Flow requirement for system within reach of fan

operation. Fans operating will ﬂoat together from minimum speed to maximum speed to keep set point.

b. If any of the fans run in the surge area for a set

time period, the BMS will need to add the bypass damper(s).

c. The PID sequence to be programmed at the BMS

for the bypass damper(s) operation. The BMS to provide fan enable and VFD speed reference.

Deﬁnition of typical operation modes:

Mode #1: Unoccupied. Deﬁned as no one inside the

lab(s), all lab hoods are closed.

1. Fan(s) will operate at BMS required speed and nozzle will modulate as necessary to achieve the required velocity out the fan(s). BMS to monitor nozzle actuator feedback for each fan and keep fan speed above the minimum required to maintain velocity.

2. Sure-Aire will measure airﬂow of the fan. VFD or the nozzle controller for each fan will report this value to BMS.

3. Duct pressure control, by the BMS, will modulate bypass damper(s) as required.

Note: Follow bypass damper(s) operation

depending on number of fans running.

4. VFD speed, duct pressure control and the bypass damper(s) operation is provided by the BMS system.

Mode #2: Occupied; no lab hoods being used. Deﬁned as people entering the lab(s), no work being done at the hoods.

2. Sure-Aire will measure airﬂow of the fan. VFD or the nozzle controller will report this value to BMS.

3. Duct pressure control, by the BMS, will modulate bypass damper(s) as required.

Note: Follow bypass damper(s) operation

depending on number of fans.

4. VFD speed, duct pressure control and the bypass damper(s) operation is provided by the BMS system.

Mode #3: Occupied; some or all lab hoods being used. Deﬁned as people in the lab(s), lab hood sashes

being used.

A. Sashes opening in the lab

1. Fan(s) will operate at BMS required speed and

nozzle will modulate as necessary to achieve the required velocity. Typical system response should be to increase fan(s) speed and increase nozzle open area.

2. Sure-Aire will measure airﬂow of the fan. VFD or the

nozzle controller for each fan will report this value to BMS.

3. Duct pressure control, by the BMS, will modulate

bypass damper(s) as required.

Note: Follow bypass damper(s) operation

depending on number of fans running.

4. VFD speed, duct pressure control and the bypass

damper(s) operation is provided by the BMS system.

VGN Technology

General Electrical Controls Information

B. Sashes closing in the lab

1. Fan(s) will operate at BMS required speed and nozzle will modulate as necessary to achieve the required velocity. Typical system response should be to decrease fan(s) speed and decrease nozzle open area.

2. Sure-Aire will measure airﬂow of the fan. VFD or the nozzle controller for each fan will report this value to BMS.

3. Duct pressure control, by the BMS, will modulate bypass damper(s) as required.

Note: Follow bypass damper(s) operation

depending on number of fans running.

4. VFD speed, duct pressure control and the bypass damper(s) operation is provided by the BMS system.

Mode #4: Fault Mode. Deﬁned as safety mode; the system has an issue and needs to default to VFD bypass.

1. VFD failure detected, automatically or manually put

into VFD bypass if available by operator or BMS.

2. Nozzle area to increase proportional to fan airﬂow

which will increase as fan speed is at maximum.

3. Sure-Aire will measure airﬂow of the fan. VFD or the

nozzle controller for each fan will report this value to BMS.

4. Duct pressure control will modulate bypass

damper(s) as required if system is in alarm mode. Duct pressure control is provided and programmed by the BMS system.

5. System manually to be reset and placed back in VFD

auto mode.

VGN Technology

General Electrical Controls Information

VGN Technology Control Flow Chart - Multiple Fans, No Staging

Positive Pressure Fault

Negative Pressure Fault

Increase

Fan(s) Speed

Send to

BMS Controller

Max. VFD

Monitor

Time

Above Setpoint

(more positive)

VFD(S) at

Full Speed

Yes

Time Period

Met?

Positive

Pressure

Alarm

Yes

BMS

Control

Drive Fault

Bypass

Mode

Fan(s) in

Stall Mode

Static Pressure

Value

Static

Pressure

= Setpoint

Static Pressure

Value

Reset at Fault Clr

Yes

Below Setpoint

(more negative)

Decrease

Fan(s) Speed

Fan Stall

Monitor Time

All Nozzle

Feedback at

Minimum

VFD(S)

Minimum

Speed

Yes

Time

Period

Yes

Reset by

BMS

Time Period

Time Met?

Period

Yes

BMS Control

Bypass Damper

PID

Min. VFD

Monitor

Time

Reset by

BMS

Yes

Drive Fault

Alarm

Fan

Full Speed

Yes

Required

Nozzle Area

VGN Technology

Above Setpoint

(more positive)

Close Bypass Damper

Bypass

Feedback

= Min. VDC

Yes

Time Period

Met?

Reset by

BMS

Static Pressure

Value

Static

Pressure

= Setpoint

Static

Pressure

Value

Below Setpoint

(more negative)

Yes

Time Period

Met?

Yes

Negative Pressure

Alarm

Feedback

= Max. VDC

NoNo

Open

Bypass

Damper

Bypass

BMS Controller

Reset at Fault Clr

Send to

Damper Position Monitor

Time

General Electrical Controls Information

Fan Operation - Multiple Fans, With Staging

Set point and minimum variables

2. Each fan to run at BMS deﬁned operation for fan staging, on or off, and event timing, as required per system airﬂow requirements. BMS is also required to control fan speed for all fans. Bypass damper mode reference will be determined by the following scenario listed:

A. One fan in system running, all other fans off.

Minimum ﬂow condition.

a. One fan in operation, BMS will control fan speed

and monitor nozzle feedback as required to maintain system set point.

b. Decreased ﬂow condition from minimum speed.

Increased ﬂow condition from minimum speed. If

c. If one fan is at maximum speed for a set time

period, another fan may be required to keep system set point. Note section B for multiple fan operation.

d. The PID sequence to be programmed at the BMS

for the bypass damper(s) operation. The BMS to provide fan enable and VFD speed reference.

B. Two or more fans running, normal operation. Fan

operation normal system ﬂow.

a. Flow requirement for system within reach of fan

operation. Fans operating will ﬂoat together from minimum speed to maximum speed to keep set point.

b. If all fans in operation are at maximum speed for

a set time period (user-deﬁned) and other fans are available, another fan can be added by the BMS as required.

c. With additional fan added to the system, all fans in

operation will decrease and match speed of new fan until set point is reached, then fans can ﬂoat together between minimum to maximum speed. Note section “C” if a dead band zone is created.

d. When more than one fan is operating and all are at

the minimum speed for a set time period and the pressure is still too negative, the BMS will need to subtract a fan.

e. When more than one fan is in operation and any of

the fans run in the surge area for a set time period, the BMS will need to subtract a fan or bypass damper(s) may need to be used.

f. With the subtraction of a fan from the system, the

BMS will need to increase speed of all remaining fans and they will ﬂoat together until set point is reached. Note section “C” if a dead band zone is created.

g. The PID sequence to be programmed at the BMS

for the bypass damper(s) operation. The BMS to provide fan enable and VFD speed reference.

C. Dead band in system. Flow between fans cycle

on/off.

Flow requirement for system out of reach causing

undesirable fan cycling on and off. If the fans in the system running at full speed is not enough air and adding an additional fan and running all fans at minimum is too much air, then the bypass damper mode may be necessary to settle these dead band zones.

a. The BMS notices and counts cycling of fans to

determine dead band zone. If a dead band is determined, the BMS will begin to modulate the bypass damper(s) open to assist with pressure control.

b. If the bypass damper(s) are at full closed for a set

time period, the BMS will increase fan speed and the fan control will increase the nozzle area as required to assist with pressure control.

c. The PID sequence to be programmed at the BMS

for the bypass damper(s) operation. The BMS to provide fan enable and VFD speed reference.

VGN Technology

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