Page 1
High Volume Low Speed (HVLS) Fan HVLS and General Ventilation Fan Control Software Installation, Operation, and Maintenance Manual HVLS/VENT MENU DOWN ENTER RECEIVING AND INSPECTION Upon receiving the control package and/or fans, check for any interior and exterior damage, and if found, report it immediately to the carrier.
NOTE: To receive warranty coverage, copy and print the “Start-Up Documentation” on page 76. Fill out the form, then fax the form to 1-919-516-8710 or call 1-866-784-6900 for email information within thirty (30) days of purchase. HVLS Extended Warranty Factory Authorized Representative Installation 7-Year Warranty:...
Warranty Conditions This warranty is not valid: • Unless the USER returns to the MANUFACTURER the “Start-Up Documentation” on page 76 within thirty (30) days of purchase. • If the product’s serial numbers have been removed or are illegible. • If 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.
INSTALLATION It is imperative that this unit is installed and operated with the designed speed range and electrical supply in accordance with this manual and applicable codes. If there are any questions about any items, please call the service department at 1-866-784-6900 for warranty and technical support issues. WARNING: TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT BEND THE BLADE BRACKETS WHEN INSTALLING THE BRACKETS, BALANCING THE BLADES, OR CLEANING THE FAN.
Remote Room Sensor/HMI Installation Do not install the room sensor on the ceiling Smart controls, remote room sensors, and remote HMI (Human Machine Interface) faceplate(s) may be ordered and shipped separately. These components measure temperature and assist in controlling the unit.
HVLS Fan Clearance NOTE: Make sure the fan is not installed above any objects that produce airflow toward fan blades. Clearances: • 60” minimum top of fan blade to roof deck • 24” minimum from fan blade to obstructions above or below •...
HVLS fan. Lights mounted above an HVLS fan can create a strobing effect if the beam (A) passes through the blades. To minimize strobing effects, increase the vertical distance (B) between the light source and fan blades.
Page 10
• The HVLS fan shall be centered approximately between four adjacent sprinklers. The vertical clearance from the HVLS fan to sprinkler deflector shall be a minimum of 3 ft. (0.9 m). • All HVLS fans shall be interlocked to shut down immediately upon receiving a water-flow signal from the alarm system in accordance with the requirements of NFPA 72.
Typical HVLS Fan and Smart Control Installation Figure 7 - VFD and Smart Control Mounting Locations VFD Mounted with Control Panel VFD Mounted with Fan Control Panel 70°F IDLE Control Panel Optional Remote Optional Remote Room Sensor Room Sensor Site Preparation - Fan 1.
I-Beam Mount Used to mount the fan directly under an I-Beam. The beam must be 3” to 10” wide and 1/4” to 1” thick. Use I-beam spacers when the beam thickness is greater than 5/8” up to 1” thick. 1. Install 1/2”-13x3” bolts with 1/2” washers through the I-beam clamp. Keep clamps as close to the beam as possible.
Concrete Beam Direct Mount Used to mount the fan directly under a single concrete beam. Minimum thickness 6” / Maximum thickness 10”. 1. Secure beam mount brackets to the concrete beam. Use four (4) 1/2” x 3” long tapcon screws with 1/2”...
Concrete Multi-Beam Mount Used to mount fan between two concrete beams. Minimum thickness 6” / Maximum thickness 10”. 1. Use the square alignment holes to keep the beam mount bracket flush with the beam. Mark the four mounting location holes. 2.
Wood Beam Direct Mount Used to mount directly under single laminated wood beam. Beams should be 6”-10” wide. 1. Secure beam mount brackets to the wood beam. Use four (4) 1/2”x13 thru-bolts (by others) with 1/2” washers. Secure with 1/2”-13 nylock nuts and 1/2” washers. 2.
Page 16
Wood Truss Mount Used to mount fan to a wood truss structure. 1. Place four (4) 1/2”x13 thru-bolts (by others) with 1/2” washers through the multi-mount bracket. 2. Place pivot extension assembly through bolts and secure with 1/2”-13 nylock nuts and 1/2” washers. 3.
You may directly mount the fan to the bottom of the OWSJ with kit HVLS-MOUNT-OWSJ-DM. You may install between the joists on the top or bottom of the OWSJ. If installing between joists, refer to “Installing Fan Between OWSJ” on page 18. All hardware must be minimum grade 8.
If installing the fan between OWSJ, the fan must be mounted to angle iron. Verify the distance between the joists. If the distance is 10 feet or less, use kit HVLS-MOUNT-OWSJ-10. If the distance is greater than 10 feet and less than 18 feet, use kit HVLS-MOUNT-OWSJ-18. The distance between the joists must not exceed a maximum distance of 18 feet.
Mounting Between OWSJ Figure 16 - OWSJ Span Installations Top Mount Max Span Bottom Mount Max Span...
Page 20
OWSJ Bottom Mount Instructions Used to mount fan between bottom of two OWSJs. 1. Place both sections of angle iron where it will be mounted. Make sure each section is overhanging the joist. 2. Install the hat channel and angle top bracket to space the angle iron. Insert 1/2”-13 x 4” bolt and washer through the bottom center hole of the hat channel.
Page 21
OWSJ Top Mount Instructions Used to mount fan between top of two OWSJs. 1. Assemble one end of the top mount bracket and hat channel, refer to Figure 19 Detail A on page 22. 2. Center the bracket on the beam. Use the holes closest to the beam, this will secure the mount. 3.
Page 22
Figure 19 - OWSJ Top Mount Assembly Details Detail A Hardware Torque 1/2” Hardware 75 Ft-lbs/101 Nm NOTE: All hardware must be minimum Grade 8. Detail B Bolts and Nuts Should Mount Between Roof Gap...
Purlin Mount Used to mount fan under minimum (4) Purlin beams. 1. Use the beam mount bracket to mark drilling hole locations. After drilling out the holes, insert 1/2”-13 x 1.5” bolts and 1/2” washers through the bracket and purlin. Secure with 1/2”-13 nylock nut and 1/2” washer.
Page 24
Figure 21 - Purlin Mount Assembly Details 1/2”-13 Nylock Nut 1/2” and 1/2” Washer Washer 1/2”-13 x 1.5” Bolt Beam Mount Plate (Small) 1/2”-13 Nylock Nut and 1/2” Washer Pivot Plate Angle Top Bracket 1/2”-13 x 1.5” Bolt 3” x 3” x 1/4” 1/2”-13 Nylock Nut Long Angle Iron and 1/2”...
Installing Pivot Mount Assembly 1. Locate where the fan will mount. 2. Install the angle top bracket and hat channel. Insert the 1/2”-13 x 4” bolt through the bottom of the hat channel. Secure with 1/2”-13 nylock nuts and washers. 3.
Tube Assembly Attention! Every connection between components (mounts, extensions, fan frame) must include a Guy Wire (safety cable), as shown throughout this manual, with loops at both ends. You may extend the length of the fan by using an extension assembly. There should be no more than 2 extensions used per fan.
Leveling Pivot Assembly After installing the fan, check the fan is level. Use the pivot adjustment bolts to level the fan. After the fan is level, tighten the pivot adjustment bolts. Install safety cables. Refer to Figure 22 and Figure 23. Figure 24 - Leveling Fan Pivot Adjustment...
Hub Assembly NOTE: The hub assembly is pre-installed to the motor assembly from the factory. Figure 25 provides reference for maintenance when required. Figure 25 - Hub Assembly Details Motor Assembly Assembly Make sure top of Tighten evenly until all Bushing bushing is flush screws are at required...
Mounting Fan to Extension Attention! Every connection between components (mounts, extensions, fan frame) must include a Guy Wire (safety cable), as shown throughout this manual, with loops at both ends. Figure 26 - Motor Assembly Mounting Details 1/2”-13x1.5” Bolt and 1/2” Washer Pivot Extension Assembly Hardware Torque...
Guy Wire Clamp Installation When placing cable clamps on the wire, it is imperative that the U-bolt slide of the clip is placed on the short turn backside and the saddle goes on the long side (the “live” end). Two clamps must be used on every safety cable end.
Blade Installation 1. Insert blade assembly into the hub slot. 2. Install 3/8”-16 x 2” inner bolt and washer into through-hole, located in the top of the motor base plate. Secure with 3/8”-16 washer and nylock nut. Torque hardware to 35 Ft-lbs/47Nm. 3.
Electrical WARNING!! Disconnect power before installing or servicing unit. High voltage electrical input is needed for this equipment. A qualified electrician should perform this work. Before connecting power to the control, read and understand the entire section of this document. As-built wiring diagrams are furnished with each control by the factory and are attached either to the door of the unit or provided with a paperwork packet.
High Voltage Wiring High voltage wiring consists of the main control panel power and wiring to and from each VFD when the VFD is panel mounted. If the VFD is remote mounted, VFD power does not need to go to the enclosure. 1.
Page 35
Figure 31 - VFD Wiring (240 Volt Single-Phase) Figure 32 - VFD Wiring (120 Volt Single-Phase)
Variable Frequency Drive (VFD) WARNING!! - Before installing the VFD drive, ensure the input power supply to the drive is OFF. - The power supply and motor wiring of the VFD must be completed by a qualified electrician. - The VFD is factory programmed, only change if replaced or ordered separately. Consult the VFD manual and all documentation shipped with the unit for proper installation and wiring of the VFD.
VFD Installation Input AC Power • Circuit breakers feeding the VFDs are recommended to be thermal-magnetic and fast-acting. They should be sized based on the VFD amperage. Refer to “ACTECH SMV VFD” on page 39. See installation schematic for exact breaker sizing. •...
VFD Programming Programming 1. The Drive should be programmed for the proper motor voltage. P107 is set to 0 (Low) if motor voltage is 120V AC, 208V AC or 400V AC. P107 is set to 1 (High) if the motor voltage is 230V AC, 480V AC, or 575V AC.
5. DDC (Direct Digital Control) Wiring: For communications from a remote Building management system, low voltage communication wiring is required. This wiring will plug into a gateway that is mounted in the HVLS panel, which then connects to J1 on the ECPM03 board via Cat 5 connection.
The VFDs (Variable Frequency Drives) included in this system have been factory programmed at 55Hz (HVLS) / 80Hz (General Ventilation Fans) for high speed and 15Hz for low speed. For HVLS fans, the speed cannot go above 55Hz. This results in a 73% reduction in airflow when operating at low speed. The VFDs are used to adjust the speed of 3 phase motors, and frequency is directly proportional to airflow.
Page 42
80°F or 28°C (activation temp + modulation band), the fan will be at its maximum speed (55 Hz (HVLS) / 80 Hz (Vent) or 100%). The maximum speed for each fan group is configurable. 4. As the temperature decreases, the speed will decrease until the temperature falls back down to the activation temperature.
In MANUAL mode, the operator can choose to start, stop, speed up, slow down, or reverse. Reverse for HVLS only the direction of fans from an HMI (Human Machine Interface). Fan faults and operating information can be viewed from any HMI as well. The chart below shows all controllable items, monitoring points, and configurable items in manual mode.
Page 44
VFD Temp °F/°C Configurable Item Range/Limit Min Speed 15 Hz to Max Max Speed Min Speed to 55 Hz (HVLS)/80 Hz (Vent) Timer Mode Auto/Off/None Timer Setting 1 to 18 Hours Temperature Units °F/°C NOTE: All fans assigned to a group will follow the commands from the HMI. They will all start together, stop together, and run forward or reverse together.
FAN function means that the FANS are turned OFF. A dark box around the FAN function means that the FANS are turned ON. For HVLS, this also applies to the FORWARD/REVERSE button. The text on the HMI shows the action that the button will produce.
Page 46
When a fault occurs, an audible alarm is triggered and a message is displayed on the HMI(s). The Audible Alarm can be silenced by pushing the Mute button that appears on the screen. At any point in time, the control can be changed from Manual to Auto mode and vice versa. This is achieved by simultaneously pressing both top buttons and holding them for 1 second.
It is extremely important not to operate the fans below 15 Hz for proper motor cooling or above a frequency that will cause the motor to over amp. The high-speed frequency has been factory programmed at 55 Hz (HVLS) / 80 Hz (Vent) to prevent this from happening.
Automatic Mode Startup During Automatic Mode Startup, it is important to verify min and max fan speed operation, group settings, and all temperature settings. All temperature sensors (HMI sensors and remote hard wired sensors) assigned to a group will average together. The averaged sensed temperature will be the temperature used for fan activation and modulation.
HMI Configuration General Overview The HMI allows the user to change between Manual Mode and Auto Mode as well as view Operating Information regarding fans, Fan Group Assignments, HMI sensor group assignments, External sensor assignments, sensor temperatures, and Fault History. At any point in time, the user can access the HMI configuration screen.
• External Sensor Readings: Shows the temperature input for all external sensors on the system. • HMI Sensor Readings: Shows the temperature input for all HMI sensors on the system. • Maintenance Log/Maintenance History (HVLS only): Allows the user to view all logged maintenance events.
HMI Menu System Overview This chart shows the menu system of the HMI. Press the two top buttons of the HMI to enter this menu system. NOTE: Each HMI must have its own unique number or address. Failure to set this up correctly will result in a Modbus communication error in the system.
This allows the board to correctly process the parameters changed. Access the Configuration menu: 1. Starting from the Main menu, which shows HVLS and the software revision, press the MENU button. Screen displays “Configuration.” Press the ENTER button. Screen displays “Enter Pass Code.”...
ECPM03 Menu System Overview NOTE: The activation temp, high temp alarm, and low temp alarm are programmed not to overlap each other. Ranges shown will be limited by activation temperature, modulation bands, and hysteresis settings. ECPM03 Configuration Details Following is a detailed list of all configurable parameters in the system. Number of Fans: This menu defines the total number of fans controlled by a single fan control system.
Page 54
Low Temperature Alarm, that sensor will cause all fans in that fan group to stop. • Reverse Temp (HVLS only): If the temperature falls below this value, the fan will run in reverse at the ‘Rev. VFD Freq’.
Page 55
HMI. Scheduling works in AUTO mode only, and fans will operate based on temperature only during scheduled times. Rev. Activation (HVLS only): Allows the fan to automatically run in reverse when the temperature is below the set reverse activation temperature range. The fan will not shut off until the temperature rises above the set range (reverse temperature + reverse hysteresis).
SET FAN GROUP MAXIMUM VFD MAXIMUM VFD FREQUENCY DEFAULT = 55 HZ (HVLS) FREQUENCY (MIN FREQUENCY - 55 HZ HVLS) DEFAULT = 80 HZ (VENT) (MIN FREQUENCY - 80 HZ VENT) GROUP SETTINGS SET FAN GROUP MINIMUM VFD MINIMUM VFD...
ECPM03 Board ECPM03 is the main control of the system. It receives all of the digital and analog inputs, and delivers all digital outputs for external devices. NOTE: Not all pins or electrical features may be used with your electrical control package. Verify with wiring schematics and/or HMI settings.
Page 58
Connector J6 contains factory only wiring for low voltage connections Pin 1 - 24V DC power input (positive side) to the board. Pin 2 through pin 7 - Each open collector relay output (RO) sources 100 mA max and is suitable for driv- ing 24V DC relays or indicator lamps.
Page 59
Connector J9 contains 120V AC control connector for factory only wiring Pin 1 - (N1) this is the neutral or return path for the detection of 120V AC by the input pins. It would be connected to the neutral side of the 120V AC supply. Pin 2 - (AR1) input, this pin can detect the presence of 120V AC.
Pressing the CLEAR button will force the HVLS control to enter the mode that it was in previous to the Emergency mode. Emergency Shutdown is the highest priority command. It supersedes all other modes, including, System Bypass, BMS mode, auto mode, and manual mode.
ECPM03 board, which will be discussed later in this manual. Once the contact is opened up between these two terminals, the HVLS control will enter the mode that it was in previous to BMS mode.
Network NOTE: The board will reboot when altering certain factory settings. Communication Module (Optional) The Communication Module, PN: SCADA, is included in all CASlink equipped panels. It obtains operational data from various connected components. This communication wiring is either RS-485 shielded twisted pair wiring or RJ45 Cat 5 Ethernet wiring.
Device Instance, MAC Address, Baud Rate Some applications may require that the Protocessor have a specific Device Instance, the default device instance is 50,000. To change the Device Instance, you must access the Web Configurator by connecting a computer to the Ethernet port of the Protocessor. The computer used must be assigned a static IP address of 192.168.1.xxx and a subnet mask of 255.255.255.0.
Changing the IP Address Some BACnet IP applications may require changing the IP address of the Protocessor. To change the IP address, go to the internal server by typing the default IP address of the Protocessor, 192.168.1.24, in the URL field of any web browser. The computer used must have a static IP address of 192.168.1.xxx. The window shown in Figure 46 appears.
LonWorks LonWorks compatibility (Figure 47) can be implemented on control packages through the ProtoNode, a LonMark certified external Gateway configured to give a Building Management System access to monitor and/or control a list of Network Variables. The ProtoNode is mounted and factory pre-wired inside the Electrical Control Panel.
The list of points that can be controlled and monitored are shown below, along with their network name and ID. When the control is configured for DDC and Auto mode, the DDC system allows the HVLS control to automatically control the fans based on its temperature sensors. BACnet OBJECT NAME...
Page 67
BACnet OBJECT NAME BACNET Modbus BACNET LON SNVT Name LON SNVT Function Default Range Description Object ID Register Data Type Type VFDFaultF4 5033 ANALOG INPUT nvoVFDFaultF4 SNVT_count Monitor Reference VFD Manual Fault Codes VFDFaultF5 5034 ANALOG INPUT nvoVFDFaultF5 SNVT_count Monitor Reference VFD Manual Fault Codes VFDFaultF6 5035...
Page 68
BACnet OBJECT NAME BACNET Modbus BACNET LON SNVT Name LON SNVT Function Default Range Description Object ID Register Data Type Type StateVFD1 5550-LB ANALOG INPUT nvoStateVFD1 SNVT_count Monitor 1 = Off by Temperature, 2 = Off by High Temperature Alarm, StateVFD2 5550-HB ANALOG INPUT...
Page 69
BACnet OBJECT NAME BACNET Modbus BACNET LON SNVT Name LON SNVT Function Default Range Description Object ID Register Data Type Type MinG5 10279 ANALOG VARIABLE nviMinG5 SNVT_count Control 15 Hz Min to Max Minimum VFD Group Frequency (Hz), 1 decimal precision, i.e. 33.5 Hz = 335 MinG6 10287 ANALOG VARIABLE...
Troubleshooting The following table lists causes and corrective actions for possible problems with the fan units. Review this list prior to consulting manufacturer. The following table lists causes and corrective actions for possible problems with the fan units. Review this list prior to consulting manufacturer. Problem Potential Cause Corrective Action...
VFD Fault List Fault Number Description No Fault IGBT Temperature Fault Output Fault Ground Fault Temperature Fault Flying Start Fault High DC BUS Low DC BUS Overload Fault OEM Fault Illegal Setup Fault Dynamic Brake Fault Phase Lost External Fault Control Fault Start Fault Incompatible Parameter Set...
HMI Fault List Fault Message on HMI Potential Cause Corrective Action Room Temperature exceeded the Verify why the temperature is so high HIGH TEMP ALARM SENSOR High Temperature Limit Fault for a and either correct the high- Fan Group. Fans in that Group shut temperature situation or raise the down.
MAINTENANCE For General Ventilation Fan Maintenance, refer to Exhaust Fan Operation, Installation, and Maintenance Manual. To guarantee trouble-free operation of this control, the manufacturer suggests following these guidelines. Most problems associated with unit failures are directly related to poor service and maintenance. Please record any maintenance or service performed on this equipment in the documentation section located at the end of this manual.
Maintenance Logging and Alerts The HVLS control system stores maintenance events in its on-board memory. These maintenance events can either be manually entered or can be logged out of the maintenance alerts that will appear on the screen at the proper time intervals.
Page 75
Maintenance Documentation Date Service Performed Date Service Performed...
Start-Up Documentation START-UP AND MEASUREMENTS SHOULD BE PERFORMED AFTER THE SYSTEM HAS BEEN AIR BALANCED AND WITH THE HEAT ON (Warranty will be void without completion of this form) Job Information Job Name Address City State Phone Number Fax Number Contact Purchase Date Quantity of Fan(s)
Need help?
Do you have a question about the HVLS and is the answer not in the manual?
Questions and answers