Rockwell Automation FANM FanMaster Energy Saving Package User Manual
FanMaster™ Energy Saving Package
Installation Manual (v2.xx)
Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls (Publication SGI-1.1 available from your
local Rockwell Automation sales office or online at
www.rockwellautomation.com/literature) describes some important differences
between solid state equipment and hard-wired electromechanical devices. Because
of this difference, and also because of the wide variety of uses for solid state
equipment, all persons responsible for applying this equipment must satisfy
themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety
considerations.
http://
WARNING: Identifies information about practices or circumstances
that can cause an explosion in a hazardous environment, which may lead
!
to personal injury or death, property damage, or economic loss.
Important: Identifies information that is critical for successful application and
understanding of the product.
ATTENTION: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or economic
!
loss. Attentions help you identify a hazard, avoid a hazard, and
recognize the consequences.
Shock Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that surfaces may be at dangerous
temperatures.
Rockwell Automation, Allen-Bradley, PanelView, PanelView Component, PowerFlex and MicroLogix are trademarks or registered trademarks of
Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Preface General Information
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1
What is Contained in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2
Chapter 1 FanMaster Overview
FanMaster Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FanMaster Externally Mounted Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
FanMaster Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
FanMaster Application Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Integration of FanMaster into Building Automation Systems . . . . . . . . . . . . . . . . . . . . 1-12
Chapter 2 FanMaster Installation
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Table of Contents
Chapter 3 FanMaster Configuration and Start Up
Using the PanelView C600 HMI Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Gather and Record Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Configure the FanMaster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
View Detailed Data Log Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Start or Stop Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Clear the Data Logs and Collect Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Chapter 4 Troubleshooting
FanMaster Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
FanMaster Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Appendix A Specifications and City Climate Profiles
Drives and FanMaster Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
City Climate Profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Appendix B FanMaster Diagrams
Drawing Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Appendix C FanMaster Screens and Field Descriptions
Dashboard Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Air Handler Unit Diagram Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Setup Screen #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Setup Date and Time Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Setup Screen #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Setup Screen #3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Supply Fan Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Return Fan Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
2
Fan Communication Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Cooling and Heating Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Proof of Flow Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Data Collection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
User City Weather Data Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14
Data Log #1 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15
Data Log #2 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16
Data Log #3 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17
System Status Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-18
Appendix D FanMaster Application Firmware Upgrades
Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Upgrade the FanMaster MicroLogix 1100 Controller Application Firmware . . . . . . . . . D-1
Upgrade the FanMaster PanelView Application Firmware. . . . . . . . . . . . . . . . . . . . . . . . D-3
Restart FanMaster with the New Application Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . D-8
Index
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
General Information
Preface
Who Should Use This Manual
What is Contained in this Manual
Manual Conventions
Use this manual if you are responsible for installing and/or operating the
Allen-Bradley® FanMaster™ Energy Saving Package (FanMaster). You
must have a thorough understanding of installation and operation of HVAC
units, Building Automation Systems (BAS) and electrical circuitry and
components in order to successfully install this product.
This manual provides installation and configuration information for the
FanMaster product only. Refer to Reference Materials on page p-2
information on associated products.
Before you begin the installation and configuration of FanMaster, it is
recommended that you read Chapter 1 - FanMaster Overview
To install and configure FanMaster, complete the instructions in each of the
following chapters, sequentially:
– Chapter 2 - FanMaster Installation
– Chapter 3 - FanMaster Configuration and Start Up
The following words are used throughout the manual to describe an action:
for
.
Word Meaning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not recommended
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
p-2 General Information
Reference Materials
Rockwell Automation publications are available on the internet at
www.rockwellautomation.com/literature
.
The following manuals are recommended for additional information:
Title Publication No.
PowerFlex 400 AC Drive Packages for Fan & Pump Applications Installation
Manual
PowerFlex 400 Adjustable Frequency AC Drive for Fan & Pump Applications User
Manual
PowerFlex 70 Adjustable Frequency AC Drive Installation Instructions 20A-IN009
PowerFlex 70 AC Drives User Manual 20A-UM001
PowerFlex 700 Adjustable Frequency AC Drive Frames 0…6 Installation
Instructions
PowerFlex 700 AC Drives Series B Vector Control User Manual 20B-UM002
PowerFlex 750-Series AC Drive Installation Instructions 750-IN001
PowerFlex 750-Series AC Drives User Manual 750-UM001
20-COMM-H RS-485 HVAC Adapter User Manual 20COMM-UM009
Wiring and Grounding Guidelines for PWM AC Drives DRIVES-IN001
PanelView Component HMI Terminals User Manual 2711C-UM001
MicroLogix 1100 Programmable Controllers User Manual 1763-UM001
22C-IN002
22C-UM001
20B-IN019
For Allen-Bradley Drives Technical Support:
Title Online at . . .
Allen-Bradley Drives Technical Support www.ab.com/support/abdrives
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
FanMaster Overview
Chapter 1
FanMaster Description
FanMaster provides a means for improving the energy efficiency of
Constant Air Volume HVAC units. Constant Air Volume HVAC units
typically draw in room air and mix it with a small amount of outside air.
This mixed air is forced by a fan through heating and/or cooling elements to
provide supply air back to the room at a temperature that makes up for
heating or cooling lost to the surrounding environment. This maintains
comfortable conditions for the building’s occupants and contents.
FanMaster improves the efficiency of a basic HVAC unit by providing the
following two additional control features:
• FanMaster replaces a fixed speed fan motor starter with a Variable Speed
AC Drive which allows the fan speed to adjust to the actual HVAC
heating and cooling loads. The Law of Affinity states that the energy
required to operate a fan decreases by the cube of the actual speed
reduction. For example, a fan running at 80% of its maximum speed
requires about 50% of the energy needed to run the fan at full speed.
And, a fan running at 50% of its maximum speed requires only about
13% of the energy needed to run the fan at full speed. FanMaster’s ability
to monitor the HVAC operation and adjust the fan speed to the required
value provides considerable opportunity for savings.
• FanMaster regulates the amount of outside air drawn into the HVAC unit
for the purpose of ventilation by monitoring the actual Carbon Dioxide
(CO
) level in the serviced space. This feature, known as Demand
2
Ventilation, maintains air quality while reducing the cost of heating or
cooling the outside air by reducing its volume.
The typical Constant Air Volume HVAC unit selected by the building's
original designer provides adequate heating, cooling, and ventilation for
worst-case conditions. The heating and cooling capacity are selected for the
coldest and hottest days anticipated and the ventilation capacity is designed
for maximum human occupancy. Since the weather is seldom at the
extremes in most locations and buildings are often occupied at less than full
capacity, FanMaster provides a savings opportunity by reducing the fan
speed and ventilation used by the HVAC unit when they are not required. In
addition, when the weather extremes do require maximum heating or
cooling or the CO
FanMaster returns the fan to its original full speed and ventilation to the
original designed value until conditions are such that it can once again
reduce the fan speed and amount of outside air ventilation.
FanMaster has been designed for installation into an existing HVAC system
with minimal interface with the existing controls. FanMaster does not
replace or interfere with the existing controls which continue to regulate
room temperature. In addition, FanMaster can also be installed and used in
an evaluation only mode (without a fan drive). This mode allows the
FanMaster energy savings calculator to provide an estimate of potential
savings, prior to performing a full installation.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
level indicates the need for maximum ventilation,
2
1-2 FanMaster Overview
FanMaster Externally Mounted Components
Temperature Sensors
Two temperature sensing probes are provided with FanMaster. These probes
are essential to FanMaster because the measured difference in temperature
between these sensors provides the command signal for the fan speed. The
temperature sensors are typically mounted on the outside of the Constant
Air Volume HVAC unit, with the sensing probe penetrating into the air flow
inside through a hole drilled into the side of the HVAC enclosure.
The placement of the Mixed Air sensor should be selected after examining
the interior of the HVAC unit to ensure that the probe is located in a position
that will accurately measure the temperature of the combined outside and
return air before entering the heating and cooling section. Avoid a location
that is in the upper, lower or edge portion of the air stream and one which
may be unduly influenced by the air entering the unit from the outside air
damper. If the Mixed Air temperature probe does not accurately reflect the
average temperature entering the heating and cooling elements, the fan
speed will not be set properly.
The supply air sensor should be mounted from 6 inches to 5 feet
downstream of the final heating or cooling element. Because the
temperature of the air can be warmer at the top of the air stream and cooler
at the bottom, the probe should be mounted as close to the vertical center of
the air flow as possible.
Carbon Dioxide Sensor
The CO2 sensor (if installed) is usually mounted in the room return air flow
of the HVAC unit prior to mixing with outside air. Alternatively, the CO2
sensor can be mounted directly on the return air duct work serving a specific
area that is most likely to be affected by high CO2 concentrations during
occasions of high occupancy. This will ensure that FanMaster will allow full
fan speed and normal ventilation when and where it is most needed. This is
the most typical installation.
Alternatively, the CO
space in an area that is most likely to be affected by high CO
concentrations during occasions of high occupancy. This will ensure that
FanMaster will allow full fan speed and normal ventilation when it is most
needed.
It may be desirable to invest in individual CO
locations. It has been found that certain buildings lack adequate ventilation
prior to installation of FanMaster. If FanMaster seems to be running in CO
override even during periods of low occupancy, it is advised that you seek
help from an HVAC air quality professional for advice on how to best
rectify the ventilation problems.
sensor can be mounted directly in the conditioned
2
2
room monitors for critical
2
2
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
FanMaster Overview 1-3
Pressure Sensor (Optional)
In certain applications it may be necessary or desirable to maintain a
positive building pressure relative to the outside air. A pressure sensor can
be ordered with FanMaster which monitors the differential pressure
between the inside and outside air. When the differential pressure is lower
than a user specified setpoint, the FanMaster will override to 100% fan
speed to try to restore the desired minimum pressure differential. One
typical scenario where pressure override might occur is when a loading
dock door is opened to allow for a delivery, and additional airflow is
required to restore the pressure differential when the door closes. The sensor
requires connection to two lengths of 1/4 inch OD plastic tubing which
sample the inside and outside air pressure at their respective termination
points. You may need to experiment with the location of the tubing since
normal wind and airflow often causes localized air pressure deviations
around a building which may result in inaccurate pressure measurements.
You may find that the HVAC unit fan speed has no measurable affect on
building pressure. In this case turn off the pressure mode completely and do
not use the sensor.
When using a pressure sensor the Constant Ventilation mode described
below is not available.
Damper Position Indicator Switch
Many existing HVAC systems have a feature known as “economizer mode”
or “free cooling mode”. These systems monitor the outside air temperature
and humidity and when conditions are such that the outside air can be used
to provide cooling (instead of using the cooling element) the existing typical
system will open the outside air damper fully to allow maximum use of this
“free” cooling. FanMaster uses a Damper Position Indicator switch to
indicate when the existing control system is in economizer mode. The
switch is installed on the outside air damper in a location that causes its
contacts to close when the damper opens beyond the normal 10%
ventilation position.
In order to take full advantage of economizer mode, FanMaster increases
the speed of the fan to 100% until the existing control determines that
economizer mode is no longer appropriate. The economizer control will
then return the damper to its normal ventilation position and the contacts in
the damper position indicator switch will open. This signal is sent to
FanMaster, which allows the fan to return to its normal reduced speed and
damper override functions.
The switch must be installed in a position that will actuate when the damper
opens. It may be mounted directly on the damper blades, on the damper
actuator arms or linkage, or on the center axle of a damper blade section.
Because there are many different damper systems in use, the installation
may require fabrication of a custom linkage or mounting method if no
suitable location is available.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
1-4 FanMaster Overview
Fan Starter Current Sensor
This device is used only when FanMaster is installed in evaluation mode.
The current sensor device is designed such that one wire lead of the existing
fan motor passes through its center. The current sensor has a switch that
actuates when it senses current flow in the motor wire, indicating that the
fan motor has been started by the existing control system. The actuated
switch identifies when the HVAC unit fan normally runs so the FanMaster
calculator can take into account the HVAC normal hours of operation and
more accurately project monthly cumulative savings.
Fan Starter Hard-Wired Interconnection
This device is used only when FanMaster is installed with a drive.
FanMaster requires a start signal from the existing BAS system in order to
know when to start and stop the fan. The control signal on the coil of the
existing fan motor starter provides this signal. The starter coil signal is
typically 115V AC or 26V AC. Two interposing relays, one that
accommodates each of these voltages, are shipped with FanMaster (120V
AC relay already installed at position CR4). Other control voltage relays are
available from Rockwell Automation.
FanMaster Operation
Fan Speed Reduction
With the installation of FanMaster, the existing HVAC control system
continues to maintain room temperature by monitoring its own temperature
sensors and controlling the heating and cooling elements. FanMaster
provides new, independent temperature sensors mounted in the airflow of
the HVAC unit. These sensors allow FanMaster to determine if the existing
controls are requesting heating and cooling and to adjust the fan speed to a
value appropriate for the amount of heating and cooling required.
As the existing controls call for more heating or cooling (as determined by
the amplitude of the temperature differential measured before and after the
heating and cooling elements), FanMaster responds by increasing the fan
speed. As the amount of heating or cooling required decreases, the
temperature differential decreases and so does the FanMaster fan speed. If
the existing controls are not calling for heating or cooling, then there is no
temperature differential across the heating and cooling elements and
FanMaster reduces the fan speed to a user specified minimum speed.
Reducing the HVAC unit’s fan speed when not calling for maximum heating
or cooling results in significant savings in the energy required to run the fan,
according to the Law of Affinity.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
FanMaster Overview 1-5
Demand Ventilation Mode
A second source of energy savings is achieved by FanMaster's Demand
Ventilation mode. A typical Constant Air Volume HVAC unit is equipped
with a damper that allows a small percentage of outside air to be mixed with
the return air, maintaining an adequate CO
occupants. The damper is typically set during installation for a fixed volume
of fresh air, adequate for the worst case condition of full occupancy. The
outside air drawn in through this damper adds to the heating and cooling
load of the HVAC unit, since the outside air is seldom at the required
temperature for the building's occupants. In fact, depending on the local
conditions, the amount of heating or cooling energy which must be supplied
to this air can be quite costly.
When FanMaster reduces the fan speed as described above, it will also
reduce the amount of outside air brought into the HVAC unit. FanMaster's
demand ventilation technique monitors the amount of CO
and will override the reduced fan speed at any time the CO
above a user specified setpoint. This feature maintains an adequate level of
ventilation while reducing the cost of heating and cooling excess outside air
whenever possible.
level for the building's
2
in the return air
2
level rises
2
The energy savings can be further enhanced by an optional feature which
allows FanMaster to fully close the outside air damper up to 50% of the
time when the CO
the damper fully, FanMaster further reduces the cost of heating and cooling
the outside air. The typical outside air damper has a spring return-to-close
mechanism and the existing controls are providing a signal maintaining the
10% open position. FanMaster provides an adjustable duty cycle electrical
relay which can interrupt the electrical signal to the damper allowing it to
close up to 50% of the time. This feature is overridden automatically by the
demand ventilation mode when the CO
setpoint.
level does not require additional ventilation. By closing
2
level exceeds the user specified
2
Variable Ventilation Mode
This mode allows FanMaster to reduce the HVAC unit fan speed and
includes the option of allowing the damper to be overridden and closed 50%
of the time, exactly as with the Demand Ventilation mode. The difference is
that with the Variable Ventilation mode there is no CO
speed and damper operation are never overridden by the demand for
additional ventilation. This mode is designed for spaces such as warehouses
or manufacturing with limited occupancy or staffing relative to the volume
of the space and thus no opportunity for buildup of excessive CO
sensor and the fan
2
.
2
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
1-6 FanMaster Overview
Constant Ventilation Mode
Constant Ventilation mode can be used in specific applications requiring a
relatively constant flow of outside air be maintained for ventilation at all
times. This mode is not recommended for most installations as it precludes
the savings which may be realized by reducing the quantity of outside air
brought into the HVAC system. This is also the most difficult installation
due to the need to redirect the control signals for the outside damper control
into FanMaster and make new interconnections from FanMaster to the
outside air damper actuator.
If this mode of operation is enabled, FanMaster will continue to reduce the
fan speed to realize savings according to the Law of Affinity, but it will also
modulate the outside air damper open as the fan slows down in order to
maintain the same approximate quantity of outside air flow into the
building.
Estimated Savings Calculator
The FanMaster control system contains a calculator that provides an
estimate of the energy savings achieved by the reduction in fan speed and
reduction in outside air heating and cooling. The calculator uses the settings
provided by the user at startup and actual operating conditions, combined
with historical weather data for your selected location, to provide the
estimated cost savings achieved by FanMaster. The estimated energy costs
to run the HVAC unit with and without FanMaster are compared to
determine the savings.
FanMaster Application Considerations
Two State Heating or Cooling Control
Two state control of heating or cooling is used when the actual amount of
heating or cooling applied by the existing HVAC unit is fixed. That is, the
heating or cooling element is either on or off. FanMaster allows for the
selection of two state control for either heating or cooling or both. When
FanMaster is configured for two state control, it will run the fan at the
configured minimum speed when the temperature sensors detect that
heating and cooling are off, and will run the fan at the configured maximum
speed when the temperature sensors detect that heating or cooling is on.
This mode allows FanMaster to achieve energy savings during the time the
HVAC unit is idle and to allow maximum performance when the HVAC unit
is actively heating or cooling.
When in two state mode, the “Delta T Min” setup values for cooling and
heating determine when the fan speed transitions from “Min” to “Max”
speed. A typical value of five degrees is acceptable for most installations.
The “Delta T Max” setup values for cooling and heating have no effect on
operation in this mode, nor do any “SA (supply air) Override” settings.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
FanMaster Overview 1-7
Proportional Heating and Cooling Control
Proportional control of heating or cooling is used when the actual amount of
heating or cooling applied by the HVAC unit is variable. That is, the heating
or cooling element is modulated by a mechanical or electrical valve. The
valve modulates how much heating or cooling is provided and is adjusted by
the existing control system to meet the actual demand. FanMaster allows for
the selection of proportional control for either heating or cooling or both.
When selected, FanMaster runs the fan at the minimum speed when the
temperature sensors detect that heating and cooling are off, and will vary the
fan from its minimum to its maximum speed proportional to the temperature
differential detected by the temperature sensors in the air flow before and
after the heating or cooling elements. This mode allows FanMaster to
achieve energy savings during the time the HVAC unit is idle and to
modulate the fan speed based on the amount of heating or cooling requested
by the existing control system, achieving an optimum energy requirement
based on the heating or cooling load.
When in proportional mode, the “Delta T Min” and “Delta T Max” setup
values for cooling and heating determine the slope of the fan speed increase.
A typical value of five degrees for “Delta T Min” is acceptable for most
installations. The “Delta T Max” setup value should be adjusted so that the
fan can achieve its maximum speed when the proportional valve controlling
heating or cooling is at 100%. The HVAC unit manufacturer can provide the
design delta T (temperature rise) of the specific unit for both heating and
cooling modes of operation. The heating delta T is typically higher than the
cooling delta T. If the unit is older or the delta T data is unavailable,
FanMaster can be initially run with the default values. The actual delta T
values of the unit can be determined by using the existing temperature
control setpoints to force the unit into a full heating or full cooling mode.
Adjust the room temperature to a very high or low setpoint and allow the
HVAC unit to run at 100% heating or cooling for about 30 minutes or until
the maximum delta T can be observed on the FanMaster System Status
screen. Perform this test for both heating and cooling. Use the actual
measured delta T values for the “Delta T Max” settings for heating and
cooling.
TIP: Although the maximum fan speed is adjustable, there is seldom a
reason to adjust this value to less than 100%. The only exception would be
for a system that is oversized to the point that the full horsepower capacity
of the fan is not required under any conditions. This could occur if the size
of the area heated or cooled is reduced after installation or if the HVAC unit
is oversized for other reasons. In this case, the maximum fan speed can be
safely reduced, provided that adequate capacity remains for extremely hot
or cold days. For reference, a reduction of the maximum speed to 95% will
deliver 95% of the airflow with a fan energy cost reduction of 16%. A
reduction to 90% reduces the fan energy cost by 23%.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
1-8 FanMaster Overview
Supply Air Low Limit / High Limit Override
The supply air limit override setup values allow you to configure FanMaster
to run the fan at full speed as the supply air temperature reaches a low or
high limit. The default values are suitable for use in most cases. It is
desirable to limit the supply air temperature extremes to protect the HVAC
equipment. Increasing the fan speed to 100% as the temperature approaches
limits will provide this protection.
The supply air low temperature limit specifies the supply air temperature
below which FanMaster will run the supply air fan at full speed (100%) to
avoid freezing up the cooling system.
The supply air high temperature limit specifies the temperature above which
FanMaster will run the supply air fan at full speed (100%) to avoid
overheating the heating system.
In many installations the supply air limit overrides will never take effect
because the system is not capable of achieving the override temperature
limits under normal conditions. Also, the override temperatures will never
be used in two state heating or cooling systems since the fan is already at
maximum speed when the delta T exceeds the delta T minimum
temperature value.
Outside Air Damper Override
Additional savings can be achieved if the installation includes an outside air
damper with spring return-to-close, the existing system provides a signal to
open the damper to its normal outside air position (typically 10%), and the
supply override relay can be wired in a manner that interrupts the existing
control signal.
Systems Without Outside Air Dampers
FanMaster can be used with HVAC systems that do not have an outside air
damper. Even though no savings can be realized by reducing outside air,
reduced fan speeds will still provide energy savings.
Heating Only or Cooling Only HVAC Systems
The setup screens provide the ability to indicate whether or not heating or
cooling elements are used in the HVAC system. Setting these fields to “No”
indicates that heating or cooling is not available and will disable that portion
of the FanMaster operation and savings calculator.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
FanMaster Overview 1-9
Multi-Stage Heating or Cooling Systems
If the HVAC system has heating or cooling elements which turn on in more
than one step (e.g., low heat or high heat) FanMaster should be configured
for proportional control. This will allow the fan to run at minimum speed if
the heating and cooling are off. The fan will step to a medium speed at low
heating or cooling and step to maximum speed at high heating or cooling.
The heating and cooling Delta T Max fields should be set to a value that
ensures that the fan actually achieves maximum speed when high heat and
high cool are on.
HVAC Systems With No Return Air (100% Outside Air)
HVAC systems that draw all the air from the outside are also known as
Makeup Air Units (MAU) and are not suitable for FanMaster installations.
FanMaster control algorithms cannot determine proper fan speeds for these
type systems and cannot be used.
HVAC Systems with Electric Heating Elements Instead of Gas
FanMaster control algorithms work with either gas or electric heating
elements; both on-off or modulating types. The FanMaster energy
calculator calculates heating costs based on the user provided cost per
MMBTU of gas. If the HVAC unit has electric heating, an acceptable
estimation of heating costs can be achieved by setting a value for gas cost to
double the prevailing utility rate (electric heat is typically twice the cost of
gas). This will allow the calculator to estimate the cost of electric heat and
thus the savings values as well. Note that the FanMaster energy calculator
results are presented for informational purposes only, and do not affect the
actual control of the fan speed.
City Climate Data
If one of the pre-loaded cities in the FanMaster database does not provide a
comparable climate for the installation location, data for a “custom city”
can be entered during configuration.
A Compact Disk containing weather data for approximately 2000 locations,
both US and worldwide, can be obtained from the National Oceanic and
Atmospheric Administration (NOAA) at this URL:
http://ols.nndc.noaa.gov/plolstore/plsql/
olstore.prodspecific?prodnum=C00515-CDR-A0001
A list of cities in the weather database on the CD is found at this URL:
http://www.ncdc.noaa.gov/oa/documentlibrary/ewdcd/
ewdstations-wmo.pdf
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
1-10 FanMaster Overview
The data set for each location on the CD contains a diagram and chart, as
shown in Figure 1.1
data to be entered into the custom user data screen. The data presents the
BTU’s per CFM of ventilation air for each month of the year for the selected
location. The energy calculator multiplies the average required BTU's per
CFM times the estimated CFM ventilation of the HVAC unit. The resultant
BTU's are multiplied by the utility costs to estimate required energy costs,
both with and without FanMaster active.
Figure 1.1 Sample NOAA City Weather Data
below. The tabulated monthly data in the chart is the
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
FanMaster Overview 1-11
Specific Setup Values
This section provides additional information for setting up specific
FanMaster configuration fields. The values entered in these fields help the
energy calculator to perform a more accurate estimate of energy savings and
are not used by the basic control algorithm and will not affect actual
savings.
• Heating Efficiency % - Use the manufacturer’s data sheet for the HVAC
unit to determine this efficiency. This value is a measure of how
efficiently the BTU capacity of the fuel purchased is converted into an
actual BTU delivered to the heated room. This value may be listed as an
AFUE (Annual Fuel Utilization Efficiency) rating. If this value is not
available, you may simply use the default value of 87% or adjust the
value up or down about 10% based on the age of the equipment (older
units typically having a lower efficiency).
• Minimum Damper Pos % - This value can best be approximated by
visually determining the angle or degree of openness of the outside air
damper in normal operation. 0% represents a damper fully closed and
100% represents a damper fully open. Typically, the damper will be
controlled by the existing HVAC or BAS system to about 10% open. If
desired, you can use a protractor to determine the actual angle and
convert it to a percentage, taking into account that dampers often appear
to be several degrees off-vertical when fully closed due to their
overlapping position. This value ultimately determines the percentage of
the total unit flow which is outside air and thus requires heating and
cooling to bring to a suitable room temperature.
Because the regulating effect of damper position on the volume of
airflow is very difficult to determine under the best of conditions, the
actual flow volume of outside air can only be roughly approximated by
this setting. However, a change in the setting of 1 or 2 percent will have a
10 or 20 percent effect in the estimations of the heating and cooling
BTU’s saved by FanMaster; so try to be as accurate as possible. This
value is used in the estimation of savings only and therefore does not
affect the actual realized savings.
• CO
Demand Setpoint ppm - If the CO2 sensor reports a value greater
2
than the setpoint, FanMaster allows the HVAC fan to increase to 100%
and will stop any override of the normal damper position. Outside air has
a typical range of 300 to 400 ppm CO
returns the interior CO
will once again reduce the fan speed to the programmed level. ASHRAE
standard 62-1989 recommends an indoor air ventilation standard of 20
cfm per person of outdoor air or a CO
Legal CO
time of exposure. Rockwell Automation recommends that you seek
guidance from appropriate federal, state, and local regulating bodies for
further information.
limits set forth by OSHA are considerably higher and vary by
2
level to the setpoint minus 50 ppm FanMaster
2
. When the added outside air
2
level which is below 1000 ppm.
2
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
1-12 FanMaster Overview
• Pressure Low Limit InWC - This value sets the minimum inside vs.
outside air pressure. If the differential is below this value (in a negative
direction) the fan speed will increase to 100%. The default value of
-0.010 means the outside air pressure is just slightly higher than the
inside air. If necessary, adjust this value so that the fan only goes into
override speed when building doors are opened or if some other factor
requires periodic additional airflow. Do not set this value such that
FanMaster is in continuous override. You may find that the HVAC unit
fan speed has no measurable affect on building pressure. In this case turn
off the pressure mode completely and do not use the sensor.
Integration of FanMaster into Building Automation Systems
FanMaster provides an alarm contact for monitoring of faults by an existing
building automation system (BAS). This contact is normally closed when
FanMaster is operating properly. If power is not supplied to FanMaster or if
FanMaster detects certain conditions (see FanMaster Alarms on page 4-2
for a complete list) the fault contact will open. The alarm panel lamp on the
FanMaster unit will also be illuminated if any of the alarm conditions are
detected. The alarm contact and alarm lamp will return to normal when the
fault condition has returned to a normal state.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
General Precautions
FanMaster Installation
ATTENTION: Only qualified personnel familiar with Heating,
Ventilating and Air Conditioning (HVAC) systems, adjustable
!
frequency AC drives and associated instrumentation and
machinery should plan or implement the installation, start-up and
subsequent maintenance of the system. Failure to comply may
result in personal injury and/or equipment damage.
ATTENTION: The following information is merely a guide for
proper installation. Rockwell Automation cannot assume
!
responsibility for the compliance or the noncompliance to any
code, national, local or otherwise for the proper installation of
this product or associated equipment. A hazard of personal injury
and/or equipment damage exists if codes are ignored during
installation.
Chapter 2
ATTENTION: FanMaster is a HVAC fan motor control device
that when integrated with HVAC building automation systems
!
and any other control devices does not provide limits for or
protection against loss of freeze status, high temperature, high
static, carbon dioxide/indoor air quality, smoke and fire, and/or
flood control signals. All persons responsible for applying this
equipment must satisfy themselves that the intended application
of this equipment is acceptable.
ATTENTION: National Codes and Standards (NEC, VDE,
BSI, etc.) and local codes outline provisions for safely installing
!
electrical equipment. Installation must comply with
specifications regarding wire types, conductor sizes, branch
circuit protection and disconnect devices. Failure to do so may
result in personal injury and/or equipment damage.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
2-2 FanMaster Installation
Installation Considerations
Consider and plan for the following when installing FanMaster for
integration with an AHU:
• The existing BAS control supply fan start/stop signal. Two relays are
provided for interfacing to the BAS fan start/stop signal. The relay
installed in the FanMaster enclosure accommodates a 120V AC signal.
A second relay is shipped loose and accommodates a 24V AC signal. If
a signal other than 24V or 120V AC is used, you must purchase and
install the appropriate relay separately. The Allen-Bradley 700-HK
family of relays provides coil voltages from 6V AC…240V AC or 6V
DC…48V DC. More information is provided on the Allen-Bradley web
site at: http://www.ab.com/en/epub/catalogs/12768/229240/229266/
229643/229701/tab3.html
• The existing BAS outside air damper position control signal (used with
constant ventilation option only). FanMaster provides I/O connections
for a 4…20 mA signal only. If the BAS control signal is 0…10V DC or
0…135 Ohms, a converter adapter must be purchased separately for
both the input and output signals.
• When installing FanMaster with a Variable Frequency Drive, the
following firmware revisions must be used:
– PowerFlex 400, v1.004 and later
Installation Requirements
– PowerFlex 70EC v3.001 and later
– PowerFlex 700VC v4.001 and later
– PowerFlex 753 v1.005 and later
Power Source for FanMaster
120V AC, 10 Amp (min.) grounded service.
Tools Required for Installation
• Variable speed drill
• Sheet metal drill bits
• Various screwdrivers
• Various wrenches (open, socket and/or torque)
• Conduit cutting and bending tools (optional, for permanent
installations)
Wiring Specifications
Important:All power, I/O and signal wiring is customer supplied.
All wire to be Stranded, copper, 600V/105 °C (194 °F) insulation.
Terminal(s) Description Max. Wire Size Min. Wire Size Torque
L, N Power 10 AWG 22 AWG 1.0 N•m (9.0 lb•in)
GND Ground 6 AWG 16 AWG 2.3 N•m (20.4 lb•in)
– I/O and Signal 12 AWG 22 AWG 0.6…0.8 N•m (4.5…7.1 lb•in)
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
Figure 2.1 Typical FanMaster and Drive Installation
FanMaster Installation 2-3
Carbon Dioxide Sensor
Air
Return
Air
Supply
Conditioned Space
AC Drive
700VC, or 753
PowerFlex 400, 70EC,
Supply Air
Tem p Tr ans
Supply Fan
(if used)
BAS Start/Stop Control
Fan Motor Current Switch
Optional Return Fan
OVERRIDE
FANMASTER
OFF ON
PanelView C600
FAULTED
FANMASTER
Mixed Air
Temp Trans
FanMaster
Switch
Damper Position
Air
Exhaust
Air
Outside
To Input Power Source
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
2-4 FanMaster Installation
Installation
Install the Instruments on the AHU
Refer to Figure 2.1 on page 2-3 the for guidance on instrument locations.
Important:Instrument cables must be no longer than 3200 m (10499 ft) for
4…20 mA signals using a minimum of 20 AWG wire and 200
m (656 ft) for digital signals using a minimum of 20 AWG
wire.
Supply Air Temperature Transmitter
• Using the two screws and mounting flanges provided on the enclosure,
mount the supply air temperature transmitter to the outside of the AHU
sheet metal cover, in the middle of the supply air plenum. Placement
must be after the heating and cooling exchangers.
Important: Verify that the transmitter probe is installed in a position
that does not cause contact with any internal equipment
and that no internal equipment will be damaged while
drilling the insertion and mounting holes.
Mixed Air Temperature Transmitter
• Using the two screws and mounting flanges provided on the enclosure,
mount the mixed air temperature transmitter to the outside of the AHU
sheet metal cover, in the middle of the mixed air plenum. Placement
should be in a position where the outside air and return air are equally
mixed and the temperature reflects the average temperature entering the
heating and cooling exchangers.
Important: Verify that the transmitter probe is installed in a position
that does not cause contact with any internal equipment
and that no internal equipment will be damaged while
drilling the insertion and mounting holes.
Carbon Dioxide Sensor
• Using the two screws and mounting flanges provided on the enclosure,
mount the carbon dioxide sensor in the return air plenum. Placement
must be prior to the mixing of outside air with the return air.
Important: The carbon dioxide sensor will not operate properly
below 0° C (32° F).
Important: Verify that the sensor probe is installed in a position that
does not cause contact with any internal equipment and
that no internal equipment will be damaged while drilling
the insertion and mounting holes.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
Damper Position Indicator Switch
FanMaster Installation 2-5
• If your installation does not
position indicator switch with the following considerations:
– The damper position switch must be installed in a location that
allows the switch to detect the damper position (e.g., on the damper
actuator crank arm).
– The damper position switch must be set to “closed” when the
outside air damper is open 5 degrees beyond the normal minimum
position for your installation.
Current Switch
• If you are installing an evaluation unit only, clamp the current switch
around any one of the supply fan motor leads.
use constant ventilation, install the damper
Install the Drive (If Applicable)
If you are installing a FanMaster evaluation unit only, continue with Install
the FanMaster Enclosure on page 2-7.
Important:If your are installing a PowerFlex 400, Style A, NEMA/UL
Type 3R, 4 and 12 drive with a factory installed HOA switch
and a speed potentiometer, you must place a jumper between
terminal 35 on TB1 in the drive enclosure and terminal 8 on the
drive signal terminal block. The Auto Start contact is not
required on this drive.
Important:If you are installing a PowerFlex 400, Style A, NEMA/UL
Type 1 drive, the optional inputs may be installed with the
exception of the Hand/Auto, Auto Start and Speed Reference
inputs.
Important:The FanMaster configuration and startup procedure (Chapter 3)
will set all necessary parameters in the PowerFlex 400 drive to
the correct settings. Therefore, those sections of the PowerFlex
400 drive installation and/or user manual which refer to setting
or configuring parameters should be ignored during
installation.
Important:PowerFlex 70EC, 700VC and 753 drives require manual
configuration of specific drive communication parameters
before completing the FanMaster configuration and startup
procedure. These steps are included later in this chapter.
Therefore, those sections of the PowerFlex 70EC, 700VC or
753 drive installation and/or user manual which refer to setting
or configuring parameters should be ignored during
installation.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
2-6 FanMaster Installation
This publication provides specific steps for interconnecting the drive and
FanMaster. For detailed drive spacing, lifting, mounting, grounding and
other detailed installation instructions, refer to the following publications:
PowerFlex 400 AC Drive
• PowerFlex 400 AC Drive Packages for Fan & Pump Applications
Installation Manual, publication 22C-IN002.
PowerFlex 70EC AC Drive
• PowerFlex 70 Adjustable Frequency AC Drive Installation Instructions,
publication 20A-IN009.
PowerFlex 700VC AC Drive
• PowerFlex 700 Adjustable Frequency AC Drive Frames 0…6
Installation Instructions, publication 20B-IN019.
PowerFlex 753 AC Drive
• PowerFlex 750-Series AC Drive Installation Instructions, publication
750-IN001.
For detailed information on how to properly wire and ground drives and
determine maximum motor cable lengths, refer to:
• Wiring and Grounding Guidelines for PWM AC Drives, publication
DRIVES-IN001.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
FanMaster Installation 2-7
Install the FanMaster Enclosure
Environment
• The NEMA/UL Type 1 enclosure is rated for an operating temperature
range of 0°…40°C (32°…104°F).
Important: The NEMA/UL Type 1 enclosure must be mounted in a
clean, dry location. Contaminants such as oils, corrosive
vapors and abrasive debris must be kept out of the
enclosure. These enclosures are intended for indoor use
primarily to provide a degree of protection against contact
with enclosed equipment. These enclosures offer no
protection against airborne contaminants.
• The NEMA/UL Type 4 enclosure is rated for an operating temperature
range of -23°…40°C (-10°…104°F).
Figure 2.2 Enclosure Minimum Mounting Clearances
25.4 mm
(1.0 in.)
FANMASTER
FAULTED
PanelView C600
NEMA/UL Type 1 Enclosure Shown
25.4 mm
(1.0 in.)
FANMASTER
OVERRIDE
OFF ON
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
2-8 FanMaster Installation
Figure 2.3 NEMA/UL Type 1 FanMaster Enclosure Dimensions
Dimensions are in mm and (inches).
580
(22.84)
495.3
(19.50)
42.40
(1.67)
247.65
(9.75)
FANMASTER
PanelView C600
FANMASTER
FAULTED
508.00
533.40
(21.00)
(20.00)
OVERRIDE
OFF ON
Ø10.4 (0.41)
Through
Mounting Holes
Typ. 6 Places
253.24
(9.97)
Side View
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
Bottom View
18.00
(0.72)
646.00
(25.45)
19.00
(0.75)
610.00
(24.00)
Figure 2.4 NEMA/UL Type 4 FanMaster Enclosure Dimensions
Dimensions are in mm and (inches).
610.00
(24.00)
572.00
(22.50)
Clearance for Ø 9.5 (3/8)
Mounting Hardware
Typ. 4 Places
673.00
FANMASTER
FAULTED
FANMASTER
OVERRIDE
OFF ON
(26.50)
FanMaster Installation 2-9
291.00
(11.47)
231.00
(9.10)
203.00
(8.00)
Side View
Bottom View
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
2-10 FanMaster Installation
FanMaster Enclosure Weights
Enclosure Enclosure Only Enclosure and Packaging
NEMA/UL Type 1 21.0 kg (46 lb) 26.3 kg (58 lb)
NEMA/UL Type 4 36.3 kg (80 lb) 41.7 kg (92 lb)
Lifting Instructions
The dimensions and weights provided above must be taken into
consideration when lifting and mounting the enclosure. Use the proper
equipment to safely lift and hold the weight of the enclosure while
mounting.
ATTENTION: To guard against possible personal injury or
equipment damage…
!
• Inspect all lifting hardware for proper attachment before
lifting the enclosure.
• Do Not allow any part of the enclosure or lifting mechanism
to make contact with electrically charged conductors or
components.
• Do Not allow personnel or their limbs directly underneath the
enclosure when it is being lifted and mounted.
Mounting Instructions
1. Verify the hole pattern on the panel to which the enclosure will be
mounted. Refer to Figure 2.3 on page 2-8
2. For NEMA/UL Type 1 enclosures, insert, but do not fully tighten, one
bolt in one of the top holes in the panel. The bolt must be fully threaded
into the panel before hanging the enclosure.
3. For NEMA/UL Type 1 enclosures, lift the enclosure and place onto the
bolt installed in the panel.
4. Install the remaining bolts into the panel and fully tighten all bolts.
or Figure 2.4 on page 2-9.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
FanMaster Installation 2-11
Wire the FanMaster and Drive (if Installed)
Refer to the FanMaster Diagrams contained in Appendix B for wiring and
connection details.
ATTENTION: Do not route signal and control wiring with
power wiring in the same conduit. This can cause interference
!
with operation. Failure to observe this precaution could result in
damage to, or destruction of, the equipment.
1. For permanent installations, determine where conduit will be routed and
prepare the FanMaster enclosure for conduit connections.
– For NEMA/UL Type 1 enclosures, remove the metal plugs in the
pre-located openings in the enclosure for conduit connections.
– For NEMA/UL Type 4 enclosures, drill the desired openings in the
enclosure to accommodate conduit connections.
ATTENTION: Protect the contents of the enclosure from metal
chips and other debris while removing the conduit opening plugs.
!
Failure to observe this precaution could result in damage to, or
destruction of, the equipment.
2. Open the FanMaster enclosure and verify that circuit breaker 1 (CB1) is
in the “off” position.
PanelView C600
FANMASTER
FAULTED
NEMA/UL Type 1 Enclosure Shown
FANMASTER
OVERRIDE
OFF ON
3. Route the power wires through the appropriate conduit (if used) and
connect to terminals L, N and G on terminal block 1 (TB1). Refer to
Wiring Specifications on page 2-2
for power wire size.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
2-12 FanMaster Installation
Important:For each installed instrument, allow for the appropriate cable
length necessary to reach the FanMaster I/O terminals in the
enclosure. Refer to Wiring Specifications on page 2-2
control wire size.
4. Wire the supply air temperature transmitter according to the
manufacturer’s instructions, route through the appropriate conduit (if
used) and connect the control wires to terminals 100, 102, 123 and 124
on TB2 in the FanMaster enclosure.
5. Wire the mixed air temperature transmitter according to the
manufacturer’s instructions, route through the appropriate conduit (if
used) and connect the control wires to terminals 100, 102, 125 and 126
on TB2 in the FanMaster enclosure.
for
6. Wire the CO
through the appropriate conduit (if used) and connect the control wires
to terminals 100, 102, 127 and 128 on TB2 in the FanMaster enclosure.
7. Wire the damper position indicator switch according to the
manufacturer’s instructions, route through the appropriate conduit (if
used) and connect the control wires to terminals 100 and 105 on TB2 in
the FanMaster enclosure.
8. If you are installing an evaluation unit, connect the control wires for the
supply fan current switch to terminals 100 and 109 on TB2 in the
FanMaster enclosure.
9. For FanMaster evaluation unit installations, continue with step 24 on
page 2-18. For installations with a drive complete the appropriate steps:
– PowerFlex 400 Drive (below)
– PowerFlex 70EC, 700VC or 753 Drive on page 2-13
PowerFlex 400 Drive
Important: A 120 Ohm terminating resistor (provided with the drive)
sensor according to the manufacturer’s instructions, route
2
must be connected to pins 4 and 5 of the RJ45
two-position terminal block adapter on the return air
drive. If a return air drive is not installed, the terminating
resistor must be connected to pins 4 and 5 of the RJ45
terminal block on the supply air drive. Refer to Figure
B.8 on page B-9 for details.
Important: The communication cable maximum length should not
exceed 500 m (1,640 ft).
a. Wire the RJ45 terminal block adapter and terminating resistor to
TB3 in the FanMaster enclosure and connect it to the PowerFlex
400 drive.
b. Continue with step 10 on page 2-14
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
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