MacroAir Technologies Controller 4 Operation Manual

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Table of Contents

Caution & Safety ................................................................................................................................. 2

Fan Network Ordering ........................................................................................................................ 3

Network Installation

Network Wiring Requirements .................................................................................................. 4

Network Wiring Conﬁgurations ................................................................................................. 5

Temp/Humidity Sensor Location (Optional) ............................................................................... 6

Network Excess Cable ................................................................................................................ 7

Wiring Diagrams ......................................................................................................................... 8

Connection Method ..................................................................................................................... 9

Temp/Humidity Sensor Installation (Optional) .......................................................................... 12

Connect Fans To Network ..........................................................................................................13

Conﬁguration and Operation

Screen Setup ............................................................................................................................... 14

Screen Flow ................................................................................................................................ 15

Controller Home Screen ............................................................................................................. 16

Setpoint ....................................................................................................................................... 17

Fan Select Screen ....................................................................................................................... 18

Fan Settings Screen.................................................................................................................... 19

Address Screen ........................................................................................................................... 2 0

Mkey ............................................................................................................................................ 2 1

Fan Diameter Screen .................................................................................................................. 22

Startup Sequence ....................................................................................................................... 23

Controller Dimensions ....................................................................................................................... 24

Warranty Information ......................................................................................................................... 25

Technical Support ............................................................................................................................... 26

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Caution & Safety

READ THE ENTIRE MANUAL BEFORE OPERATING THE FAN. Ensure that all safety practices and instructions are followed during the installation, operation, and servicing of the fan. Failure to apply these safety practices could result in death or serious injury. If you do not understand the instructions please call our Technical Department for guidance (Technical Support contact information can be found on page 26.

All fan controls and incoming power should only be installed by qualiﬁed technicians familiar with the requirements of the NEC and local codes. Refer to appropriate portions of this manual for other important requirements. Failure to follow these guidelines will void the manufacturer’s warranty.

Installation is to be in accordance with the national electrical code, ANSI/NFPA 70-1999 and local codes.

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH.

Read and understand this manual before installing or operating a fan unit. Installation, adjustment, repair, or maintenance must be performed by qualiﬁed personnel.

The user is responsible for compliance with all international and national electrical code requirements with respect to grounding of all equipment.

Many of the parts of this unit operate at line voltage. DO NOT TOUCH.

Install all covers before applying power or starting and stopping the unit.

DAMAGED EQUIPMENT

Do not operate or install any fans or fan accessories that appear to be damaged.

Failure to follow this instruction can result in death, serious injury, or equipment damage.

MAINTENANCE AND SERVICE:

If the fan does not operate properly using the procedures in this manual, BE CERTAIN TO REMOVE ALL POWER TO THE UNIT and contact our technical department for further assistance.

Keep all body parts clear of moving part at all times.

All electrical troubleshooting and repair must be done by a qualiﬁed technician and meet all applicable codes.

REFER TO FAN INSTALLATION MANUAL(S) FOR FURTHER MAINTENANCE INFORMATION.

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Fan Network Ordering

It is important to purchase fans that are setup for a network. MacroAir customizes fans to operate in a network by:

1) Addressing the fans and

2) Supplying an additional 15ft piece of CAT5

Note: If you did not order your fans for a network by default they will all have Node Address “2”, and you will be missing necessary materials. Contact technical support to modify your fans for networking.

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Network Wiring Requirements

Network Wiring Requirements:

• Use of Twisted Pair, CAT5e (or higher grade) shielded cable

• Minimum 24 AWG (0.5mm) cross section

• Ground the shielding and drain wire at only one point of the cable run

• Route wires as far away as possible from high voltage AC cables, ﬂuorescent lights, arc welders, and other equipment that transmits EMI (electromagnetic interference).

Networked MacroAir fans must be connected in one single line, referred to in this document as a “daisy chain”. The characteristics of a proper daisy chain are: one beginning (Controller 4) and one end (last fan). If the fans are not connected in one line/chain there will be a de-gradation of the communication signal and the network may not function as intended (fans in the network may not operate).

Daisy Chain

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Improper Wiring Conﬁguration

One Beginning, One End

Proper Wiring Conﬁguration

Network Wiring Conﬁgurations

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Temp/Humidity Sensor Location

(Optional)

The optional sensor can be placed between two fans or between the controller and a fan as per the diagrams below. Refer to page 12 for more information.

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Excess Cable at Connection Point

Trim Excess Cable

Network Excess Cable

With noise being emitted throughout a typical industrial/commercial environment, extra cable should not be coiled up as the coil itself will create noise/interference in the communication signal. There should be no more than two feet of excess cable at each connection point.

If more than two feet of cable is needed for future relocation of the fan, run the cable up toward the ceiling and back down in a horseshoe shape.

ALWAYS AVOID SHARP BENDS OF THE CABLE.

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Wiring Diagrams

Typical T-Splice of CAT5

Wiring: CAT5 Pin-Out

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Connection Method

1. Take the incoming CAT5 from the network, the CAT5 from the fan, and the CAT5 going to the

rest of the network. Give some slack (no more than 24”) on each CAT5 to strip the wires and splice them together. Run the slack up towards the ceiling and back down in a horseshoe shape.

DO NOT roll the excess slack into a circle or coil because this creates a place for the network to pickup noise on the lines.

2. Strip jacketing off the three CAT5 cables and separate each color wire leaving approximately 2

inches of each wire exposed including the drain/shield wire.

3. Strip approximately 1/2 inch off each color wire leaving the bare copper exposed.

2 inches

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Connection Method

4. Twist the 3 wires of same color from each CAT5 together.

5. Place a gel ﬁlled bean crimp onto the end of the 3 wires and use a small crimper or pliers to

crimp the bean tight on the wires.

6. Double check that the 3 drain wire/bare wires are also crimped together as this is what

continues the shielding throughout the network. The shielding and drain wire MUST be connected to Earth Ground at only one point of the cable run.

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Connection Method

7. Repeat steps 3-5 for all the wires.

8. Once all the wires are crimped, carefully twist the wires up. Then fold them back and tape them

up with electrical tape to clean up your wiring.

9. Make sure to tape or zip tie all 3 CAT5 lines to the structure to support the 3 way splice and

provide strain relief.

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Temp/Humidity Sensor Installation

(Optional)

Mounting

1. Mount the ﬂoor temperature sensor in the room where the fan/fans are placed within 3ft of the ground. Use caution when placing the sensor making sure not to place it where there is any contact with direct sunlight. Refer to the wiring diagrams on page 8 for placement in the CAT5 run.

2. Once the module has been placed it can be wired into the network. Use the brown pair to power the temperature sensor and the blue pair for communication. If there is enough slack in the cable you can run the wiring directly in and out at the same point on the sensor module.

3. If there is not enough wire to pull in and out of the sensor splice a length of cable keeping length to a minimum. Use the bean crimps supplied by Macro Air to wire the lead into the network. Please refer to network wiring diagram on the following page.

Please refer to the wiring diagram below:

Note: This section of the manual is applicable only if you ordered optional temperature

sensor feature.

Brown - 24VAC- jumpered to GND Brown/white - 24VAC+ Blue - Net+ Blue/white - Net-

WARNING:

Do not mount the temperature probe on metal as it will then be reading the temperature

of the metal rather than the air temperature.

PINOUT:

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Connect Fans To Network

Instructions:

1. Refer to the fan installation manual(s) for fan installation instructions. Fans that are ordered for

networks are labeled with their assigned addresses. Take note of the addresses and ensure that

the fans are installed in the desired locations.

2. Mount the controller in the desired location.

3. Connect all fans as described in the previous pages. Ensure that the 15 ft CAT5 cables are

connected directly to the fans.

4. Review safety and caution information in the fan installation manual(s) and apply power to all of

the fans.

Controller

CAT5 Cable

(100 ft)

CAT5 Cable (15 ft)

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The touchscreen may require additional setup before operating the fans. Please refer to the steps below to properly conﬁgure your controller.

1. Power on the fans. The screen will illuminate as soon as power is supplied.

2. The screen will search for fans and take you to the home screen once the scan is complete.

3. AVD 370, AVD3-430, and AirVolution fans do not require further setup. If you only have these

fans on the network, set a speed and direction using the buttons on the home screen. AirVolution fans will operate normally. AVD 370 and AVD3-430 fans will spin in reverse at a preset speed, automatically determine the blade length, and resume operation at the speed and direction commanded.

4. AVD3-450, 550 and 780 fans REQUIRE the blade size to be programmed in order to function

correctly. The blade size is set via the “Settings” (pg 19). Once the size is programmed into every AVD3-450, 550 and 780 on the network, the fans can be operated normally.

Screen Setup

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Screen Flow

Home Screen - Pg 16 Setpoint - Pg 17 Fan Select - Pg 18 Fan Settings - Pg 19 Fan Address - Pg 20 Mkey - Pg 21

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Home Screen

The home screen allows control of all connected fans. Selecting a speed and direction will cause all fans to run simultaneously. The fans will not run unless speed AND direction commands are given.

Reverse: Issues a reverse command to all fans

Forward: Issues a forward command to all fans

Power: Turns the fan off if running; turns the fans on if a speed and direction were previously

selected

Down/Up Arrows: Adjust the speed up and down. The speed is displayed as a percentage in the middle

Light: Turns the light on or off

Settings: Accesses the Fan Select page, from which the settings page can be accessed

Right Arrow: Navigates to the fault code page

Mode: Changes to reﬂect what mode the controller is in, which is selectable via the setpoint

screen. Manual mode indicates that the fans are controlled manually via the controls. Temperature mode indicates that the fan will turn on and off according to the temperature set point. Humidity mode indicates that the fan will turn on and off according to the humidity set point

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Setpoint

The Setpoint page allows you to select the method of control for your fans, as well as the desired temperature or humidity setpoint if the optional sensor is installed.

Mode Selection: Allows you to choose between manual mode, temperature mode, and humidity mode. Manual mode allows you to control the fan from the home screen. Temperature mode runs the fan according to the speed and direction set on the home screen once the measured temperature is greater than the set point temperature. Humidity mode runs the fan according to the speed and direction set on the home screen once the measured humidity is greater than the set point.

Set Point: Displays the temperature or humidity threshold

Temperature Reading: Displays the ambient temperature. Will read “BAD TEMP READING” if

there is no sensor connected

Humidity Reading: Displays the ambient humidity. Will read “BAD HUMID READING” if there is no sensor connected

Change Units: Changes the Temperature Reading and Set Point between Fahrenheit and Celsius

Left Arrow: Navigates to the Home Screen

Right Arrow: Navigates to the Fan Select screen

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Fan Select

The Fan Select page displays a button for every fan connected to the controller*. Pressing the button for the desired fan will take you to that fan’s Settings page. Pressing the left arrow will take you back to the Setpoint page.

* If fans are connected, but not displayed on the Fan Select screen, check your CAT5 connections. Call technical support if you require further assistance.

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Fan Settings

Selecting a fan will take you to the fan’s settings page. Here you can view various data points on the fan.

RPM: Displays the current speed of the fan

Blade: Displays the blade size. Pressing here will allow you to program the blade size for AVD

550s, 780s, and AVD3-450s.

Motor Type: Displays the fan model

Tilt: Displays the tilt of the fan. This feature is only available on AVD 550, 780, and AVD3-450 fans

and will always read 0 for 370 and AVD3-430 fans

Motor Temp: Displays the temperature of the motor

Heatsink Temp: Displays the temperature of the heatsink

FW: Displays the ﬁrmware version number of the AirBrain

Left Arrow: Takes you to Fan Select

Right Arrow: Takes you to address page

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Address

The address page allows you to change the Modbus address of the fan. This is useful for programming fans for the controller that were not originally shipped with the controller. Please note that each fan must have a unique address, so be careful when making any changes to ensure that there are no address conﬂicts. Only one fan can be connected when changing address.

Up/Down Arrows: Adjusts the address number shown on the screen. Ensure that this number is unique for every connected fan

Reset Drive: Resets the AirBrain. Address changes do not take effect until the drive is reset

Left arrow: Takes you to Fan Settings

Right Arrow: Takes you to Mkey

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Mkey

The Mkey page prevents unauthorized users from accessing advanced settings on the fan that could potentially cause damage if misused. For access to advanced settings, please call Technical Support at 866-668-3247.

Mkey: Displays a code that needs to be relayed to Technical Support for a password. This code is constantly changing, so you must be in front of the screen when on the phone with MacroAir

Number pad: Technical support will issue you with a 4 digit number once you provide the Mkey. The 4-digit code can be typed in using the number pad. Please note that the buttons will beep, but nothing will show on the screen. After the 4 digits are typed in the keypad will automatically take you to the Calibrate screen

Left Arrow: Takes you to the Address page

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Fan Diameter

The Fan diameter page allows you to set the diameter on 550, 780, and AVD3-450 fans. These fans will not run properly if the diameter is not set correctly. This screen is reached by pressing the “Blade” section of the Fan Settings Screen.

Up/Down Arrow: Adjust the diameter up and down. For AVD3-450 fans, adjust the diameter past 24 to access 3-blade fan settings

Left Arrow: Takes you to the Home Screen

Right Arrow: Takes you to the Startup Sequence page

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Startup Sequence

The startup sequence page allows you to automatically detect the blade size on AVD 550, 780, and AVD3-450 fans without manually inputting the diameter on the Fan Diameter page. Press “3-Blade” for AVD3-450 fans and “6-blade” for 550/780 fans.

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Controller Dimensions

LCD Screen

Enclosure

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Warranty Info

MacroAir 3-Year Controller Limited Warranty

MacroAir Technologies, Inc. Warrantor: The warrantor for the limited warranties set forth herein is MacroAir Technologies Inc. (“MacroAir”). Limited Warranty: This limited warranty (this “Warranty”) applies only to the original End-User (the “End-User”) of any MacroAir Technologies’ Three or Six Blade fan Controllers, Network Controllers or AIRLYNK Building Management System interfaces hereafter referred to as the “Product” and cannot be transferred. This Warranty applies even in the event that the Product is initially sold by MacroAir for resale to an End-User. What This 3 Year Warranty Covers: MacroAir warrants that the Product will have a “service life” (deﬁned below) of Three Years from the date of purchase (the “Three-Year Service Life”) when used in accordance with the operation and maintenance procedures prescribed in the MacroAir Installation and Owners Manuals and Controller Instructions. If MacroAir ﬁnds, in its sole discretion, that any Product has not provided the Three-Year Service Life, MacroAir will, as its sole obligation and the End-User’s sole remedy for MacroAir’s breach of this warranty, repair or replace the Product, at its option, F.O.B. MacroAir’s factory, for a charge, payable by the End-User to MacroAir on the following basis: What This Limited Warranty Does Not Cover: This Warranty does not cover any defects or damages caused by: (a) failure to properly store the Product before installation; (b) shipping and delivery of the Product if shipping is FOB Factory; (c) neglect, accident, abuse, misuse, misapplication, or incorrect installation; (d) repair or alteration not authorized in writing by MacroAir personnel or performed by an authorized MacroAir Customer Service Engineer or Agent; (e) improper testing, operation, maintenance, adjustment, or modiﬁcation of any kind not authorized in writing by MacroAir personnel or performed by an authorized MacroAir Customer Service Engineer or Agent; or (f) use of the Product under other than normal operating conditions or in a manner inconsistent with the Product’s labels or instructions.

APPLIES TO ALL MACROAIR PRODUCTS:

Any Warranted Items repaired or replaced pursuant to this Warranty will be warranted for the remaining portion of the original Warranty subject to all the terms thereof. MacroAir shall not be responsible for any charges for testing, checking, removal or installation of Warranted Items not authorized in writing by MacroAir personnel or performed by an authorized MacroAir Customer Service Engineer or Agent. Limitation Of Liability: The remedies of the End-User set forth herein are exclusive and are the sole remedies for any failure of MacroAir to comply with its obligations hereunder. In no event shall MacroAir be liable in contract, in tort (including negligence or strict liability) or otherwise for damage to property or equipment other than the Products, including loss of proﬁts or revenue, loss of use of Products, cost of capital, claims of customers of the End-User or any special, indirect, incidental or consequential damages whatsoever. The total cumulative liability of MacroAir hereunder whether the claims are based in contract (including indemnity), in tort (including negligence or strict liability) or otherwise, shall not exceed the price of the Product on which such liability is based. MacroAir shall not be responsible for failure to provide service or parts due to causes beyond MacroAir’s reasonable control. End-User’s Obligations: In order to receive the beneﬁts of this Warranty, the End-User must use the Product in a normal way; follow the Product’s Installation and Owners Manuals; and protect against further damage to the Product if there is a covered defect. Other Limitations: MacroAir’s obligations under this Warranty are expressly conditioned upon receipt by MacroAir of all payments due to it (including interest charges, if any). During such time as MacroAir has not received payment of any amount due to it for the Product, in accordance with the contract terms under which the Product is sold, MacroAir shall have no obligation under this Warranty. Also during such time, the period of this Warranty shall continue to run and the expiration of this Warranty shall not be extended upon payment of any overdue or unpaid amounts. Costs Not Related To Warranty: The End-User shall be invoiced for, and shall pay for, all services not expressly provided for by the terms of this Warranty, including without limitation, site calls involving an inspection that determines no corrective maintenance is required. Any costs for replacement equipment, installation, materials, freight charges, travel expenses or labor of MacroAir representatives outside the terms of this Warranty will be borne by the End-User. Obtaining Warranty Service: Call MacroAir Technologies Inc., Customer Service Department at

909.890.2270. MacroAir will not accept any product for return, credit or exchange unless expressly

authorized by MacroAir in writing and delivered FOB MacroAir factory with proper Return Authorization Number attached to the product.

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Technical Support

For installation assistance, application questions, technical support & any other inquiries, please contact our Technical Support team at (866) 668-3247.

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