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Electronically Commutated Motors
INSTALLATION, OPERATION & MAINTENANCE MANUAL
IM-4055
April 2012
Electronically Commutated Motors
Electronic commutation (EC) is the latest motor technology to be used in direct drive fans. Also known in the industry as Brush Free or Brushless DC, the EC motors utilize an electronic circuitboard to control the functionality of the
motor. The motor operates off of 115V AC single phase power, which is converted to DC power within the motor’s
circuitry. The result is a highly efficient motor with an expanded speed control range and a variety of speed control
options to choose from.
General Installation
CAUTION: Sheet metal parts, screws, clips and similar items inherently have sharp edges, and it is necessary that the
installer and service personnel exercise caution.
The installation of this equipment shall be in accordance with the regulations of authorities having jurisdiction and all
applicable codes.
This equipment is to be installed by an experienced installation company and fully trained personnel.
Verify that the wheel rotation is correct. It should be CW when viewed from the shaft end (CCW from opposite shaft end).
Refer to IM-4050, IM-4205 or IM-4800 for detailed installation instructions on the fans that utilize EC motors.
Do not operate the fan beyond the maximum cataloged RPM. The current should be verified any time the RPM is
adjusted to ensure it is below the nameplate amperage value.
Electrical Connection
1. Connect supply wiring to the disconnect switch (non-fused standard).
2. The motor is factory set at the voltage marked on the fan nameplate. Check the line voltage with the nameplate
voltage.
3. The main power wiring should be sized for the ampacity shown on the dataplate. Size wires in accordance with
the ampacity tables in Article 310 of the National Electrical Code. If long wires are required, it may be necessary to
increase wire size to prevent excessive voltage drop. Wires should be sized for a maximum of 3% voltage drop.
CAUTION: Use copper conductors only.
CAUTION: Protect wiring from sharp edges. Leave some slack in the line to prevent damage.
4. Disconnect switches are not fused. The power leads must be protected at the point of distribution in accordance
with the fan dataplate.
5. All units must be electrically grounded in accordance with local codes or, in the absence of local codes, with the
latest edition of the National Electrical Code (ANSI/NFPA 70). A ground lug is provided as standard in the unit terminal box. Size grounding conductor in accordance with Table 250-95 of the National Electrical Code. DO NOT use
the ground lug for connecting a neutral conductor.
6. Supply voltage to the power ventilator should not vary by more than 10% of the value indicated on the unit dataplate. Phase unbalance must not exceed 2%.
©2012 Twin City Fan Companies, Ltd.
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Speed Control Options
Three speed control options are available for the Twin
City Fan EC motor. Coming standard with the motor
is both a motor mounted dial, for speed adjustment at
the fan (first option), and a 0-10V DC control lead. The
0-10V DC control lead can be used with a remote speed
control, either field supplied (second option) or supplied
by TCF (third option).
1. Motor Mounted Dial – A potentiometer is mounted
to the motor housing offering full speed control range.
Speed adjustment is made with a
small flat head screwdriver. With
this option, the motor’s 0-10V DC
control leads are terminated in a
standard 2x4 junction box from the
factory and can remain there if not
required by the end user.
2. 0-10V DC Lead – A 36” long control lead is prewired
from the motor which accepts a 0-10V DC signal and
can be wired into building control systems or field supplied controls. With this option, the control leads are terminated in a standard 2x4 junction box from the factory.
Field supplied controllers should be provided and installed by others and send the motor a 0-10V DC signal.
A 24V AC source is also required to power the controls
in the motor. Note that the motor mounted dial acts as a
speed reference for this option. In order to have the full
speed control range available
for a given fan/motor combination, the motor mounted
dial must be turned all the
way in the CW direction or to
the maximum RPM allowable
for the fan/motor combination (look for labels on fan). The motor operates off of
a 2-10V DC signal while the motor will be off when a
0-1.9V DC signal is present.
CAUTION: Always disconnect power before inspection or
maintenance. Although motor may be off and not running
when a 0-1.9V DC signal is present, high voltage will still
be present at the motor.
3. Remote Mounted Dial – A wall mounted dial allows the
fan to be controlled from within the building by sending the motor a 0-10V DC option. This option includes
a 115V to 24V AC transformer mounted in the NEMA
electrical enclosure. On models DCRD,
DCRU/R, DCRW/R and DCLH/P the junction box for the transformer will be located within the fan motor enclosure. On
models DSI and TCPE, the junction box
for the transformer will be located on the
exterior of the fan.
With this option a 3 wire control cable
must be field supplied and wired from
the 24V AC transformer box to the re-
mote location of the controller. In addition, a standard
2x4 single gang electrical junction box (by others) is
required to mount the controller. The maximum distance
from the remote mounted controller to the motor is 100
feet. Distances greater than this could cause a loss of
the signal to the motor and result in unstable motor
performance.
On the back of the remote mounted dial there is a small
switch which will allow the user to change the output of
DIAL OUTPUT
SELECTION SWITCH
the remote mounted dial. The settings of the switch are
0-10V or 2-10V. A label on the rear of the controller’s
printed circuitboard describes the settings. The motor
will run regardless of which setting the dial is at, but
because the motor operates off of a 2-10V DC signal,
it will be off when a 0-1.9V DC signal is present. If the
user requires the remote mounted dial to turn off the
motor, the dial should be set at 0-10V DC.
With the field supplied 3 wire control cable connections
from the transformer box to the remote mounted dial
must be made as follows:
Connection in
Transformer Box
Yellow/White Common 1
Blue/Black 24V AC 2
Red 0-10V DC 3
The user should verify that the dial is properly working
by adjusting the dial and checking that the motor speed
changes accordingly. The voltage at the dial should also
be verified. 24V AC should be present across terminal
1 and 2. Terminals 1 and 3 should have a DC voltage
in the range of 0-10V DC which should vary as the dial
is adjusted.
Note that the motor mounted dial acts as a speed reference for this option. In order to have the full speed
Description Terminal on
3 WIRE CONTROL CABLE
CONNECTION TERMINALS
Back of Dial
2 Twin City IM 4055
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control range available for a given fan/motor combination, the motor mounted dial must be turned all the way
in the CW direction or to the maximum RPM available.
Maintenance
Keep motor dry and free of dirt, dust and debris.
Figure 1 below is a detailed wiring diagram for the Remote Mounted Dial option.
CAUTION: Always disconnect power before inspection or
maintenance. Although motor may be off and not running
when a 0-1.9V DC signal is present, high voltage will still
be present at the motor.
Figure 1. Remote Mounted Dial Wiring Diagram
POWER
LEADS
GROUND
BLACK
WHITE
Troubleshooting
Remote Dial does not vary the motor speed
• Verify that correct connections are made (refer to
page 2)
• Make sure that the connections are solid
• Check control input voltage at connection (inside
transformer box)
• Make sure that the dial on the motor is opened CW
CONTROL
LEADS
RED
MOTOR
WHITE
BLACK
GROUND
WHITE
DISCONNECT
BOX
BLACK
FIELD INSTALLED
FACTORY PROVIDED
YELLOW
COM
120 VAC
24 VAC
REMOTE DIAL (TCF)
1
BLUE
SIGNAL
3
0 - 10 V
2
24 VAC
3 Twin City IM 4055
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Limitation of Warranties and Claims
Seller warrants to the original purchaser that the goods
sold hereunder shall be free from defects in workmanship and material under normal use and service (except
in those cases where the materials are supplied by the
buyer) for a period of one year from the date of original
installation or eighteen (18) months from the date of
shipment, whichever occurs first. The liability of seller
under this warranty is limited to replacing, repairing, or
issuing credit (at cost, F.O.B. factory and at seller’s
discretion) for any part or parts which are returned by
buyer during such period provided that:
a. seller is notified in writing within ten (10) days fol-
lowing discovery of such defects by buyer, or within
ten (10) days after such defects should reasonably
have been discovered, whichever is less;
b. the defective unit is returned to seller, transportation
charges prepaid by buyer.
c. payment in full has been received by seller or said
products; and
d. seller’s examination of such unit shall disclose to its
satisfaction that such defects have not been caused
by misuse, neglect, improper installation, repair,
alteration, act of God, or accident.
No warranty made hereunder shall extend to any seller
product whose serial number is altered, effaced or
removed. Seller makes no warranty, express or implied,
with respect to motors, switches, controls, or other
components of seller’s product, where such components
are warranted separately by their respective manufacturers. THIS WARRANTY IS EXPRESSLY IN LIEU OF
ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
WHETHER STATUTORY OR OTHERWISE, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. In no event
shall seller be liable to buyer for indirect, incidental collateral, or consequential damages of any kind.
(BUYER’S FAILURE TO PAY THE FULL AMOUNT DUE
WITHIN SIXTY (60) DAYS OF DATE OF INVOICE SHALL
OPERATE TO RELEASE SELLER FROM ANY AND ALL
LIABILITY OR OBLIGATION ARISING PURSUANT TO
ANY WARRANTY, EXPRESS OR IMPLIED, WHETHER
STATUTORY OR OTHERWISE, INCLUDING ANY IMPLIED
WARRANTY OR MERCHANTABILITY OR FITNESS FOR
A PARTICULAR PURPOSE, MADE IN CONNECTION
WITH ANY CONTRACT FORMED HEREUNDER. BUYER
AGREES THAT SUCH FAILURE TO PAY SHALL
CONSTITUTE A VOLUNTARY WAIVER OF ANY AND ALL
SUCH WARRANTIES ARISING PURSUANT TO SUCH
CONTACT.)
Twin ciTy fan & blower | www.Tcf.com
5959 Trenton Lane N | Minneapolis, MN 55442 | Phone: 763-551-7600 | Fax: 763-551-7601
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