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Direct Drive HVLS Fan

User's Manual

E506041

User’s Manual

Installation, Operations

Maintenance and Parts

Do not install, operate, or service this product

unless you have read and understand the

Safety Practices, Warnings, and Installation and

Operating Instructions contained in this manual.

Failure to do so could result in death or serious

injury.

This manual applies to fans manufactured

beginning September 2021.

Part No. 6022221B

Summary of Contents for 6022500

Page 1: ...stall operate or service this product unless you have read and understand the Safety Practices Warnings and Installation and Operating Instructions contained in this manual Failure to do so could resu...

Page 2: ...A part of ASSA ABLOY ASSA ABLOY...

Page 3: ...r the VFD panel not including the touchscreen The warranty for the touchscreen is one 1 year Exclusions to the limited warranty U S and Canada only For international contact the factory This Limited W...

Page 4: ...HARDWARE 14 FAN KIT 15 PACKING KIT STANDARD 15 REQUIRED TOOLS 15 PRIOR TO FAN INSTALLATION 15 FOR OPTIONAL NETWORK IFAN OR MULTI FAN FANS ONLY 16 INSTALLATION CONSIDERATIONS 17 ROOF SLOPE 17 ROOF ANGL...

Page 5: ...ANDARD INSTALLATION 6015291 42 FIRE CONTROL SYSTEM FAN SHUTDOWN NETWORK INSTALLATION 6020547 43 550 600V SUPPLY WIRING DETAILS OPTIONAL 44 HMI SETUP 45 DEFINE THE NUMBER OF FANS 45 SET THE DIAMETER OF...

Page 6: ...LT CODE DEFINITIONS 53 PASSCODE PROTECTION 54 MULTI FAN CONTROL OPTIONAL 55 TEMPERATURE CONTROL OPTIONAL 55 PLANNED MAINTENANCE 57 ANNUAL MAINTENANCE 57 TROUBLESHOOTING GUIDE 59 VARIABLE FREQUENCY DRI...

Page 7: ...icons and fields are highlighted in bold text z Text highlighted in blue indicates a link you can click to navigate to another topic INTERACTIVE ONLINE ELEMENTS These elements are available in the onl...

Page 8: ...afety messages that follow this symbol to avoid possible death or injury DANGER SYMBOL Indicates an imminently hazardous situation which if not avoided will result in death or serious injury ELECTRICA...

Page 9: ...u do not understand the instructions ask your supervisor for instruction To reduce the risk of personal injury do not bend the blade brackets when installing the brackets or cleaning the fan Do not in...

Page 10: ...red architect Improper installation of the fan could result in death or serious injury Before service inspection or cleaning make certain the power is disconnected and properly locked out If the fan d...

Page 11: ...rical wiring and other hidden utilities Exercise caution and common sense when powering the fan Do not connect the fan to a damaged or hazardous power source Do not attempt to resolve electrical malfu...

Page 12: ...industrial fan Nameplates cautions instructions and posted warnings shall not be obscured from the view of operating or maintenance personnel for whom such warnings are intended Warnings which are wor...

Page 13: ...equipped with sprinklers including ESFR sprinklers shall comply with the following z The maximum fan diameter shall be 24 feet 7 3m z The fan shall be approximately centered between four adjacent spr...

Page 14: ...tener torque requirements Description Torque Wrench size 1 2 dia mount hardware 44 48 ft lbs 3 4 hex 3 8 dia blade mount hardware 24 28 ft lbs 9 16 hex Cable clamp guy wire Secure tight 5 16 nut drive...

Page 15: ...4 5 16 z Torque wrench 15 60 Ft lbs for use with sockets z Wire strippers z 1 4 cable cutter z Tape measure z Spirit level short z Gloves z For laminated wood beam installations a drill and 1 2 dia d...

Page 16: ...ovember 2022 Fan Kit FOR OPTIONAL NETWORK IFAN OR MULTI FAN FANS ONLY Ensure the Fan Network Address number matches the network layout drawing where applicable Consult the square Network Address label...

Page 17: ...3 between blades and typical obstructions DIRECT DRIVE FAN Roof Slope 0 2 12 3 12 4 12 Hanging Weight LB Maximum Torque Ft Lb Roof Angle 0 9 5 14 0 18 4 Blade Length in Fan Diameter Extension require...

Page 18: ...into exclusion zones Regularly inspect fans to ensure exclusion zones remain clear of interference before operating the fan All fan blade parts must be greater than 3 from all obstructions including...

Page 19: ...such as diffusers radiant heaters exhaust fans louvers etc the HVLS fan must be installed at minimum distances Refer to the figures below Fans located above HVAC equipment must have a minimum clearan...

Page 20: ...ive HVLS Fan UM November 2022 Installation Considerations Fans located at or below HVAC equipment musts have a minimum clearance of greater than or equal to 2 fan diameters See Figure 3 Figure 3 Great...

Page 21: ...lumns greater than 1FT wide should have a minimum distance of one half 1 2 fan diameter from the end of the blade Fans located above solid obstructions such as racks walls etc must have a minimum dist...

Page 22: ...d beam mounting use the laminated wood beam kit available from 4FRONT Ensure fan blade clearance meets the requirements shown in Figure 1 through Figure 5 NOTE Consult a professional engineer or regis...

Page 23: ...ion Considerations NOTE If the fan is part of a networked system ensure placement is in accordance with the building layout The fan network is located on the front panel of the VFD box Be sure to comp...

Page 24: ...lade plane INSTALL FAN MOUNT 1 Fasten the pivot brackets to the extension tube with ears outboard 2 Leave the 1 2 dia x 4 1 2 bolts and nylock nuts finger tight See Figure 6 STANDARD I BEAM 1 Locate t...

Page 25: ...dia grade 5 thru bolts and the self locking nuts not supplied 2 Ensure the brackets are square to the bottom of the beam 3 Attach the mount assembly to the laminated wood beam brackets using the suppl...

Page 26: ...ware to attach the powerhead to the bottom of the mount assembly See Figure 11 5 Immediately attach the safety cable The torque rating must be 44 48ft lbs See Figure 11 a Slide two of the supplied 1 4...

Page 27: ...it as other motor cables If you mount multiple VFD panels in the same location tie the grounds in series 1 Mount the VFD box outside the fan blade arc Orient the box so that the front panel is accessi...

Page 28: ...If you have used a mounting extension make sure you use the longer guy wires accompanying the extension Ensure the angle formed by the guy wire with the roof structure is less than 45 See Figure 14 A...

Page 29: ...head unit hangs plumb Use a spirit level to verify the power head unit hangs plumb 8 Tighten the pivot and angle the adjustment bolts on the fan mount 9 Torque to 44 46 ft lbs See Figure 16 INSTALL MO...

Page 30: ...plied lock nuts provided for blade mounting 1 Remove the special blade retention lock nuts 2 With the blade oriented so that the blade retention lanyard is on top support the blade assembly from below...

Page 31: ...ARANCE AND CABLE TENSION 1 Rotate the fan by hand and observe the clearance of each blade with the closest obstruction If necessary reposition the fan NOTE Blade tips droop when they are not in operat...

Page 32: ...at the remote end PROTECT these ferrules during cable routing 2 Route the remote signal blue cable 6015651 from the top of the VFD box through the hole in the factory supplied junction box 3 Wire the...

Page 33: ...oltage and phase of the incoming power agrees with the label on the top of the VFD box and fan Be certain the power is off when wiring to the control box Failure to do so may result in electrical shoc...

Page 34: ...0Hz 1 2kW 5 6 FLA 230V 60HZ VFD 100 120 1PH 1HP 0 75KW 4 2A 200 240 3PH 3HP 2KW 10A 200 240 3PH 3HP 2KW 10 0A O L 4 2 6 0 5 6 3PH WIRING DETAILS Figure 23 2 1 FU106 600V 16A DISCONNECT DS103 1 2 3 4 5...

Page 35: ...E KTKR10 KTKR5 KTKR10 KTKR5 MOTOR 0 8kW 6 0 A FLA 230V 60HZ 0 8kW 6 0 FLA 460V 60HZ 1 2kW 5 6AFLA 230V 60HZ 1 2KW 2 8 FLA 460V 60HZ VFD 200 240 3PH 1PH 3HP 2KW 10 0A 380 480 3PH 3HP 2KW 5 0A 200 240 3...

Page 36: ...36 6022221B Direct Drive HVLS Fan UM November 2022 Electrical Schematics VARIABLE FREQUENCY DRIVE I O Figure 24 TOC...

Page 37: ...BUILDING FIRE ENCLOSURE AS POSSIBLE SUPPLY VOLTAGE 115VAC SUPPLIED BY ENTREMATIC AS AN OPTION FG VDC GND D D WHITE GREEN RED BLACK FAN N DATA0 DATA0 Vs GND DATA1 DATA1 1 10 11 20 RS485 REPEATER 60191...

Page 38: ...D 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 PCB SD RH PC 24 24 EN EN C C D D D D 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 PCB SD RH PC 24 24 EN EN C C D D D D 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 PCB D D SC HVLS FAN ENCLOSU...

Page 39: ...NG DETAILS OPTIONAL Figure 27 MODBUS TEMP HUM SENSOR CONTROLLER MODBUS ADDRESS 100 OUTPUTS POWER 24VAC J1 J6 RS485 BLACK RED HMI DATA HMI DATA HMI GND HMI VDC HMI F G C C EN EN 24 HVLS VFD ENCLOSURE 2...

Page 40: ...sed NC contacts must be dry contacts They open in the event of an active alarm ENABLE THE FIRE CONTROL SHUTDOWN The fire control system fan shutdown option is not enabled when shipped To enable the sh...

Page 41: ...fire control system fan shutdown operation 1 Remove the wire from the NC contact at the building fire control panel See Figure 24 The fan should coast to a stop To enable the fire control system fan s...

Page 42: ...42 6022221B Direct Drive HVLS Fan UM November 2022 Electrical Schematics FIRE CONTROL SYSTEM FAN SHUTDOWN STANDARD INSTALLATION 6015291 Figure 29 TOC...

Page 43: ...5 Y4 Y3 Y2 Y1 Y0 C1 C0 PLC TB1 FA ALARM FIRE CR PC D PC D PC SG FROM PC REMOTE IN BELDON 8723 FAN D FAN D FAN SG TO INITIAL FAN REMOTE OUT BELDON 8723 PLC POWER PLUG 1 2 3 RS 485 PLC WIRE LEGEND FIELD...

Page 44: ...ing must be installed in accordance with any national state or local code requirements The transformer assembly is rated for one single fan load only Each fan must have its own step down transformer a...

Page 45: ...the prompts on the HMI screen to complete these tasks DEFINE THE NUMBER OF FANS 1 Press the number of fans 1 6 the HMI will control See Figure 33 The number you selected changes to green SET THE DIAME...

Page 46: ...Press Yes to enable the temperature control OR Press No to disable 2 Press the right arrow to continue See Figure 32 If you enable Temperature control the temperature settings screen SET THE TEMPERATU...

Page 47: ...FIGURATION If you make an error when configuring the HMI program you can go back to the Main setup screen to correct it To access the Main screen 1 Press the menu icon in the bottom left hand corner o...

Page 48: ...es the use of an anemometer supplied by 4FRONT 6020770 1 Attach a 3 4 schedule 40 pipe 1 06 dia or 1 dia structural pipe fitting to the outside of the structure so that it protrudes no less than 24 ab...

Page 49: ...nstructions OPERATING INSTRUCTIONS FAN CONTROL SCREEN Figure 36 Start Stop RPM increase Reverse Forward RPM decrease Menu Fan speed Previous fan multi fan only Next fan multi fan only Active alarm see...

Page 50: ...correct z The clearance from obstructions matches the requirements z All safety cables are present and properly installed z All fasteners are properly torqued z No personnel are in the movement area...

Page 51: ...eed is 1 CHANGE THE FAN DIRECTION It is not necessary to stop the fan to change its direction z Select Forward or Reverse to change the fan direction DIAGNOSTIC SCREEN The Diagnostic screen shows the...

Page 52: ...larm displays press the Fault Codes button to display the fault codes See Figure 39 If the fan is currently under a Fault Code the Active Default displays in the Active Fault Code screen If the fan is...

Page 53: ...ge during deceleration stop 48 Inverter overload 49 Motor overload 82 Input phase loss 96 Stall prevention 112 Brake transistor alarm 128 Ground fault overcurrent at start 129 Output phase loss 144 Ex...

Page 54: ...u have customized your passcode enter your customized passcode ENABLE YOUR PASSCODE By default the passcode is disabled Press the unlocked padlock icon to enable the passcode entry requirement DISABLE...

Page 55: ...button and then press the Temp button 3 Type the temperature to start the fan automatically See Figure 44 At this temperature the fan automatically starts at speed 2 4 Type a value to increment the t...

Page 56: ...rature decreases until the temperature falls below the start point When the temperature falls below the start point minus the increment value the fan automatically shuts off The fan stops on its own D...

Page 57: ...E 1 Inspect the control panel for loose connections and tighten as required 2 Use dry air shop air blow out debris from fan motor cooling fan NOTE The fan motor cooling fan is located on the top of th...

Page 58: ...Direct Drive HVLS Fan UM November 2022 Planned Maintenance Figure 45 Legend Symbol Description Cleaning Frequency Quarterly Blow with Compressed Air Frequency Annually Visually Inspect Replace Damaged...

Page 59: ...ng and repair must be done by a qualified technician and meet all applicable codes Do not route control wiring for any other device through the control box Ensure that the voltage and phase of the inc...

Page 60: ...fire circuit is open A Red fire alarm indicator displays The fire alarm is active if the fire circuit is open Review the building fire system and reset it if necessary The fan is operating but turnin...

Page 61: ...during deceleration or stop E OV1 Regenerative overvoltage trip during acceleration E OV2 Regenerative overvoltage trip during constant speed E OV3 Regenerative overvoltage trip during deceleration or...

Page 62: ...NEMA 1 z Solid State VFD Variable Frequency Drive z 120VAC 1PH before the 208 240VAC z 208 240VAC 1PH 208 480 VAC 3PH z Line reactor where required z Class CC fuses z UL and UL C listed panel and comp...

Page 63: ...November 2022 6022221B Direct Drive HVLS Fan UM 63 Components and Specifications Figure 47 VFD box VFD unit Safety cable Universal mount Guy wires Winglet Clamp Powerhead Motor cover Blade TOC...

Page 64: ...not interfere with the safe normal operation of the product must be used Incorporation of replacement parts or modifications that weaken the structural integrity of the product or in any way alter the...

Page 65: ...November 2022 6022221B Direct Drive HVLS Fan UM 65 Parts List FAN Figure 48 16 15 17 3 4 7 13 14 12 8 10 9 11 19 6 8 20 Laminated wood beam shown for clarification 5 21 18 TOC...

Page 66: ...clamp 1 4 PLD 441103 5 1 HVLS Ext Mnt 12 optional 6015865 HVLS Ext Mnt 24 optional 6015866 HVLS Ext Mnt 36 optional 6015867 HVLS Ext Mnt 48 optional 6015870 HVLS Ext Mnt 60 optional 6015869 HVLS Ext M...

Page 67: ...nsion STD 6022261 20 1 Laminated Wood Beam Bracket Set Optional 6018028 21 5 8 Black Blade Assy 6020503 10 Black Blade Assy 6020504 12 Black Blade Assy 6020505 14 Black Blade Assy 6020506 16 Black Bla...

Page 68: ...PANEL 120V 1P 10FT 6022504 VFD PANEL 120V 1P 12FT 6022508 VFD PANEL 120V 1P 14FT 6022512 ITEM QUANTITY DESCRIPTION PART NUMBER 1 1 Interface HVLS DIN Mount 6015547 2 1 Mitsubishi VFD DD 120V 1P 602207...

Page 69: ...1 3 2 FUSE 15A 600V KTKR15 6011800 4 1 ROTARY DISCONNECT 6021193 5 1 DISCONNECT HANDLE 6021191 6 1 DISCONNECT SHAFT 150MM 6021194 VFD PANEL 230V 3P VFD PANEL 230V 3P 8FT 6022502 VFD PANEL 230V 3P 10FT...

Page 70: ...V 3P 14FT 6022515 VFD PANEL 480V 3P 16FT 6022519 VFD PANEL 480V 3P 18FT 6022541 VFD PANEL 480V 3P 20FT 6022544 VFD PANEL 480V 3P 24FT 6022547 ITEM QUANTITY DESCRIPTION PART NUMBER 1 1 INTERFACE HVLS D...

Page 71: ...ANEL Figure 50 WHT BRN GRN BRN WHT GRN 2 1 3 ITEM QUANTITY DESCRIPTION PART NUMBER 1 1 Touch screen Controller Kelley 6015758 Touch screen Controller Serco 6015759 Touch screen Controller Epic 6023293...

Page 72: ...72 6022221B Direct Drive HVLS Fan UM November 2022 Parts List TEMPERATURE CONTROL OPTIONAL Figure 51 ITEM QUANTITY DESCRIPTION PART NUMBER 1 1 Temp Control Assembly 6022769 TOC...

Page 73: ...November 2022 6022221B Direct Drive HVLS Fan UM 73 Notes NOTES TOC...

Page 74: ...ASSA ABLOY 2021 Corporate Office 1612 Hutton Drive Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 Please contact your local distributor for assistance TOC...

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