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FanMaster™ Energy Saving Package

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2. ob ololblbbboboololooobooobbboboobbbb PRPPRPRR PRR ERR popi Pepee 000000000000000 D sooo 0 TT l eee TB3 L sm mn Oo _ Label Component Slot 0 MicroLogix 1100 Programmable Controller Slot 1 Analog Input Expansion Module CB2 Circuit Breaker for controller and analog input module power PS1 Power Supply 120V AC input 24V DC output CR1 Contact Relay for supply fan running signal CR2 Auxilary Contact Relay for supply fan running signal CR3 Spare Contact Relay for customer use CR4 Contact Relay for BAS Controller start signal TB3 Modbus communication adapter TB2 Primary I O terminal block CB1 Circuit Breaker for panel power TB1 Power input terminal block HTR1 Enclosure Heater Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 B 18 FanMaster Diagrams Notes Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Appendix C FanMaster Screens and Field Descriptions This chapter contains a description of the inf
3. 2 Non shielded wires to be Belden No 3105A or equal 3 Shielded cable to be a Belden No 3106A or equal To Sheet 2 i TERM Factory Installed Jumpers Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster TB1 120V AC Input o z BAS Damper Override Control Output To Sheet 2 Customer Supplied 120V AC 50 60 Hz Power FanMaster Diagrams B 11 Figure B 10 Interconnect Diagram for PowerFlex 700VC Drive Sheet 1 PowerFlex 700VC FanMaster Drive I O TB TB2 ro 16 135 Drive Running Signal 120V AC N Fan Running Input Supply Fan Drive 20 COMM H TB TB3 Optional Position GND RS 485 cable de SHED Command to Damper SHIELD pa A SHLD Signal 4 20 mA i CoM E COM A Drive I O TB B l l l B su sss u was 7 AO 1 A J w q A L 6 _JA0 1 Com TERM TERM qt Dd oi Installed Jumpers PowerFlex 700VC Signal RS 485 TB1 L Customer Return Fan Drive 120V AC Input Supplied N gt 120VAC Optional s l susu Power 20 COMM H TB eno C LDH SHIELD COM Bp A TERM D Damper Position Switch In Econ Mode TB2 Signal 24V DC Black 100 Econ Mode Switch 24V DC
4. Damper Override changes to display No Damper Override If the FanMaster will override the BAS control of the outside air damper press the value next to Override Duty Cycle and enter the percent of time the outside air damper will be closed during a 20 minute cycle time Enter a value between 10 50 10 2 minutes closed 18 minutes open 50 10 minutes closed 10 minutes open Maximum savings setting 50 If a pressure sensor is not used continue with step 40 If a pressure sensor is used press the value next to the Pressure Low Limit inWC field and enter the inWC value below which FanMaster will command the supply fan speed to increase in order to maintain the appropriate pressure level If a CO sensor is installed press the value next to the CO2 Demand Setpoint ppm field and enter the CO parts per million ppm at which outside air ventilation should occur In this case 60 seconds after the value in this field has been exceeded FanMaster will release override control if enabled of the outside air damper allowing it to return to the normal position open and the supply fan to ramp to 100 speed until the CO level is 50 ppm below the setpoint Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Configuration and Start Up 3 13 41 If a CO sensor is installed press the value next to the CO2
5. Heating Setup Delta T Min The difference in temperature between the mixed air and supply air at and below which the drive will run the supply fan at the minimum speed when heating the conditioned space Delta T Max The difference in temperature between the mixed air and supply air at or above which the drive will run the supply fan at the maximum speed when heating the conditioned space VFD Output Min The percentage of full speed that the drive will run the supply fan when the temperature difference is at or below the minimum value in Delta T Min when heating the conditioned space VFD Output Max The percentage of full speed that the drive will run the supply fan when the temperature difference is at or above the maximum value in Delta T Max when heating the conditioned space SA High Limit Override Supply Air High Limit The supply air high temperature limit above which FanMaster runs the supply air fan at full speed 100 in an attempt to avoid overheating the heating system AHU Press to view the Air Handler Unit Diagram Screen PNLVW_ Press to access the PanelView Configuration Main screen where you can choose to Config upgrade the FanMaster PanelView application firmware Factory Secured access setup for factory use only Only Back Press to view the Fan Communication Setup Screen Next Press to view the Proof of Flow Setup Screen Allen Bradley FanM
6. YYYY Year selection Choose the year for which you want to view data Monthly Fan cost without Monthly energy cost in dollars to run the fan s without using FanMaster FanMaster Monthly Fan cost with Monthly energy cost in dollars to run the fan s using FanMaster FanMaster Monthly Outside Air Monthly cost in dollars to heat the outside air without FanMaster Heating cost w o FanMaster Monthly Outside Air Monthly cost in dollars to heat the outside air using FanMaster and the Heating cost with outside air damper override FanMaster amp Override Monthly Outside Air Monthly cost in dollars to cool the outside air without FanMaster Cooling cost w o FanMaster Monthly Outside Air Monthly cost in dollars to cool the outside air using FanMaster and the Cooling cost with outside air damper override FanMaster amp Override Monthly Total HVAC Operational Hours The number of hours that the HVAC fan s has run per month Dashboard Press to view the Dashboard Screen AHU Press to view the Air Handler Unit Diagram Screen System Status Press to view the System Status Screen Data Log Screen you are currently viewing Back Press to view the Data Log 1 Screen Next Press to view the Data Log 3 Screen Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 Data Log 3 Screen FanMaster Screens and Fiel
7. 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 CO3 level in the serviced space This feature known as Demand 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 FanMast
8. 15 O 4 4 mm UY i Crt o 14 A O Com TERM yen Installed Jumpers PowerFlex 400 Signal RS 485 f TB1 Return Fan Drive T gt customer Optional 120V AC Input N oe Surpa See Note 4 s L so Hz Power RJ45 RS 485 A 120 Ohm Termination Resistor See Note 7 Damper Position Switch In Econ Mode I TB2 Signal 24V DC Black 1 100 Econ Mode Switch 24V DC Red 105 Input Signal for Econ Mode Switch TB2 BAS Outside Air Customer Supplied Line 119 _ BAS Damper Override Damper Override Control 120 f Control Output Signal Customer Selected Line Common Customer Supplied Nuetral Notes 1 All power I O and signal wire is customer supplied A A 2 Non shielded wires to be Belden No 3105A or equal 3 Shielded cable to be a Belden No 3106A or equal To Sheet 2 To Sheet 2 4 On PowerFlex 400 style A NEMA UL Type 3R 4 amp 12 drives jumper TB1 35 in the drive enclosure to drive signal terminal 8 5 CR4 in FanMaster to be 700 HK32A24 for 24V AC or 700 HK32A1 for B Pin 4 120V AC BAS Start Signal 6 For drives with Full Feature Bypass only connect terminals 61 and 162 on FanMaster TB2 to terminals 34 and 36 on TB1 in the enclosure as shown Pin1 N Resistor 7 It the optional return fan is not used move the termination resistor to the gt supply fan terminals A and B 8 When using a PF400 drive with a full feature bypass and speed pot add new Us 1 switch contact part number 800F X10 to the H
9. Supply Air Low Limit 45 Detta T MIN Delta T MAK VFO Output MIIN VFO Output MAX Supply Air High Limit FACTORY ONLY Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Screens and Field Descriptions C 11 Table C J Cooling and Heating Setup Screen Fields Heading Field Name Description Cooling Setup Delta T Min The difference in temperature between the mixed air and supply air at and below which the drive will run the supply fan at the minimum speed when cooling the conditioned space Delta T Max The difference in temperature between the mixed air and supply air at or above which the drive will run the supply fan at the maximum speed when cooling the conditioned space VFD Output Min The percentage of full speed that the drive will run the supply fan when the temperature difference is at or below the minimum value in Delta T Min for Cooling when cooling the conditioned space VFD Output Max The percentage of full speed that the drive will run the supply fan when the temperature difference is at or above the maximum value in Delta T Max for Cooling when cooling the conditioned space SA Low Limit Override Supply Air Low Limit The supply air low temperature limit below which FanMaster runs the supply air fan at full speed 100 in an attempt to avoid freezing up the cooling system
10. O284 2009 15 15 21 Press the value next to the Set Month field and enter the current month 1 12 22 Press the value next to the Set Day field and enter the current date 23 Press the value next to the Set Year field and enter the current year in the format ccyy 24 Press the value next to the Set Hour field and enter the current hour military 24 hour format 25 Press the value next to the Set Minutes field and enter the current minutes 26 Press Press To Accept to set the current date and time Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 3 10 FanMaster Configuration and Start Up 27 Press Next The second Setup screen displays Evaluation Unit Install Only Permanent Install Only PF4DD FULL FEATURE BY PF400 BASIC B P HEATING PROP BACE NEXT 28 If you have installed an evaluation unit continue with step 29 below If your installation contains a drive select the Drive Type used for the AHU see Available Drive Types on page A 5 for a description of each available drive Press the up and down arrows ras gl below the list to scroll to and choose a type Press Enter ial to apply your selection The selected type will be highlighted Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN
11. DC contact closed when open gt minimum Economizer active BAS Start full only 115V AC or 24V AC signal Current Switch evaluation unit only DC contact closed when fan running Supply Fan Drive Running Contact on drive closed when supply fan drive running Supply Fan Drive Status and Speed Feedback via Modbus RTU Return Fan Drive Status and Speed Feedback via Modbus RTU when installed Outside Air Damper Command from BAS required only w constant vent option 4 20 mA 0 100 open command Pressure optional w pressure override 4 20 mA 0 100 0 100 InWC building pressure to outside pressure difference Outputs High CO2 Alarm Isolated contact closed Supply Fan Proof of Flow Isolated contact closed FanMaster Not Faulted Isolated contact closed Damper Override force outside air damper closed used only when not using constant vent option Isolated contact closed Damper Command to Outside Air Damper connect at supply fan drive analog output 1 terminals required only w constant vent 4 20 mA 0 100 open command Supply Fan Start Stop and Speed Reference via Modbus RTU Return Fan Start Stop and Speed Reference via Modbus RTU when installed Instrumentation Temperature Transmitter 2 0 100 C 32 F 212 F Duct Insertion CO Sensor 0 2000 ppm Duct Mount Damper Switch Type Mechanical Rating 5 A 120 250V AC Operation SPDT Angle N O make
12. Auxiliary Contact Relay for supply fan running signal CR3 Spare Contact Relay for customer use CR4 Contact Relay for BAS Controller start signal TB3 Modbus communication adapter TB2 Primary I O terminal block CB1 Circuit Breaker for panel power TB1 _ Power input terminal block Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Diagrams B 17 Figure B 16 FanMaster NEMA UL Type 4 Enclosure Layout S e O E Pea g D c D _ Cc r r l EET H w9 OOO o7 OO eya OTOT lig SooS HEH ad loldld 1 See t wo oleo o P J P LA g a mi T ir Z O D 5 PLC O TB2 SLOT 0
13. L1 L2 amp L3 Replace the existing wiring with new longer wires of the same gauge and rating if required Remove the motor output side from the existing fan motor starter contactor and reconnect to the drive motor terminals T1 T2 amp T3 Replace the existing wiring with new longer wires of the same gauge and rating if required Connect the existing BAS supply fan start stop signal wires to terminals 159 and 160 on TB2 in the FanMaster enclosure Important A 120V AC relay 700 HK32A1 is installed labeled CR4 in the FanMaster enclosure at the factory for the BAS supply fan start stop signal If your installation requires a relay for a 24V AC signal you must remove the factory installed relay and install and wire the 24V AC 700 HK32A24 relay provided or the appropriate relay for your installation Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Installation 2 15 14 If the existing fan motor starter provides an auxiliary open or closed contact when the relay is energized normal operation of the existing control system may not be possible without this contact Therefore disconnect the wires from the fan motor started contact and connect it to the appropriate auxiliary contact terminals provided in the FanMaster enclosure The FanMaster auxiliary contacts actuate when the drive is on and turning the fan Refer to the schematic diag
14. 2 Restarting FanMaster with New Application Firmware D 8 Return Fan Comm Fault alarm 4 3 Return Fan Drive Fault alarm 4 3 Return Fan Setup screen C 9 S Schematic Diagrams B 1 Setup Date and Time screen C 5 Setup screen 1 C 4 Setup screen 2 C 6 Setup screen 3 C 7 Setup Values At Defaults Perform Setup Per User Manual alarm 4 4 Specifications Input Power A 1 Instrumentation A 2 PowerFlex 400 Drive Ratings A 1 Torque 2 2 Wire 2 2 Speed Pot Operation A 5 Standards and Certifications A 1 Startup FanMaster 3 1 Stop Data Collection 3 27 Supply Air Low Limit High Limit Override Applying 1 8 Supply Air Temperature High alarm 4 3 Supply Air Temperature Low alarm 4 3 Supply Air Temperature Out Of Range alarm 4 2 Supply Fan Comm Fault alarm 4 3 Supply Fan Drive Fault alarm 4 3 Supply Fan Setup screen C 8 System Status screen C 18 Index 3 Systems Without Outside Air Dampers Applying 1 8 T Temperature Sensors Installation Considerations 1 2 Torque Specifications 2 2 Two State Heating or Cooling Control 1 6 U Upgrading Firmware MicroLogix Controller D 1 PanelView D 3 User City Weather Data Setup screen C 14 Using the PanelView C600 HMI Terminal 3 1 V Variable Ventilation Mode 1 5 View Detailed Data Log Information 3 26 W Web Sites see WWW World Wide Web Weights FanMaster Enclosures 2 10 Wire Specifications 2 2 Wiring BAS Supply Fan Start Stop 2 14 CO2 Sensor 2 12 Damper Position
15. AC 2 2 37 kW 2 2 250 kW 3 50 Hp 3 350 Hp 12 88 A 4 8 460 A PowerFlex 70EC Drive Ratings 200 240V AC 400 480V AC 600V AC 0 37 18 5 kW 0 37 37 kW 0 37 37 kW 0 5 25 Hp 0 5 50 Hp 0 5 50 Hp 2 2 78 2 A 1 1 72A 0 9 5 A PowerFlex 700VC Drive Ratings 200V AC 400V AC 600V AC 0 5 100 Hp 0 37 132 kW 1 0 150 Hp 2 5 260 A 1 3 260 A 1 7 144 A 240V AC 480V AC 690V AC 0 5 100 Hp 0 5 200 Hp 45 132 kW 2 2 260 A 1 1 248 A 52 142 A PowerFlex 753 Drive Ratings 400V AC 480V AC 0 75 250 kW 1 350 Hp 2 1 456 A 2 1 415 A FanMaster Energy Saving Package Category Specification Standards and UL508A Certifications Ambient Temperature NEMA UL Type 1 NEMA UL Type 4 Limit for Enclosure 0 40 C 32 104 F 23 40 C 10 104 F Types Intended for indoor use only Do not install in direct sunlight Input Power 120V AC 10 Amp min grounded service User Interface PanelView Component C600 HMI Terminal Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 A 2 Specifications and City Climate Profiles Category Inputs and Outputs e e e Specification Inputs Supply Air Temp 4 20 mA 0 100 C 32 212 F Mixed Air Temp 4 20 mA 0 100 C 32 212 F CO 4 20 mA 0 2000 ppm Damper Position Switch when not using constant vent option
16. Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B 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 prevaili
17. Crossover EtherNet Cable 1763 NC01 Modbus Cable and Adapter a PanelView C600 t 1100 102 PanelView 2 sl e Sasi TB2 TB2 _TB2 _TB2 Is 2 Cra At _ freq a ss BAS Start from Building Controller 24V AC or 120V AC TB2 CR4 1 TB2 Note 24V AC or 120V AC heH 11 p4 ieg See from the BAS controller will Interposing Contact Note activate CR4 which provides i for ae rae H one contact to signal the for use with Full Feature Bypass A See Figure B 8 Interconnect Diagram Sheet 1 MicroLogix 1100 controller to start FanMaster operation A second contact is CR4 3 provided for customer use 1 21 124 109 D BAS Controller lI Fan Start To Sheet 1B 100 24V DC 102 0V DC To Sheet 1B To Sheet 1B Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Diagrams B 3 Figure B 2 FanMaster w Drive Schematic Diagram Sheet 1B From Sheet 1A MicroLogie 1100 From Sheet 1A Base I O D A Slot 0 100 24V DC Supply Fan Inputs 102 OV DC Running To Sheet 2B 102 CR1 1 DC Com 11 14 103 o TB2_ TB2 i Line Damper in Signal 105 R 00 Econ Mode Switc
18. Drive Running Relay Contact Te b N nja Terminals on PF400 Drive E 1 120V AC A2 ZNAI i N R5 R4 H135 1 Supply Fan Running al iN A From Sheet 1B CR1 3 140 21 24 Lia CR1 4 214422 2 MRAN CR2 1 145 Ay 14 Las CR2 2 ANAE Haar CR2 3 148 21 24 49 CR2 4 213122 liso 151 A2 oR3 A His2 CR3 1 isah 11 j E CR3 2 My 42 IE CR3 3 156 21 24 157 7 CR3 4 ate Le Supply Fan Running Auxiliary Contacts Supply Fan Running Auxiliary Contacts Supply Fan Running Auxiliary Contacts CR3 Spare for Customer Use Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 B 6 CB1 FanMaster Diagrams TB1 Customer s Incoming No 120V AC 60 Hz 1 Phase Power Figure B 5 FanMaster Evaluation Unit Schematic Diagram Sheet 1A Power Supply 120V AC In 24V DC Out 1606 XLE120E PS1 24V DC 100 Ty 101 F 0V DC 102 5A 24V DC Heater Enclosure Heater 1 1 NEMA UL I Type 4 Only 1 L
19. EN P December 2009 PN 65329 D 8 FanMaster Application Firmware Upgrades 13 Press Change Startup Application to confirm your choice The File Manager screen displays again Main File Manager File Manager Source A Internal Communication Fantlastrv Startup Application Display Date and Time System Information 14 Press Run below the list Loading displays for a short time The Important Notice screen displays 15 Verify that you the correct firmware version displays in the lower left corner of the screen The firmware version also displays in the lower left corner of the Dashboard screen Restart FanMaster with the 1 Turn off power to FanMaster by setting circuit breaker 1 CB1 in the New Application Firmware enclosure to the off position 2 Remove the USB thumb drive from the back of the Panel View terminal 3 Re apply power to FanMaster by setting circuit breaker 1 CB1 to the on position This will load the new MicroLogix application firmware A message may display indicating that a new program has been loaded and that the FanMaster configuration procedure must be completed Confirm the message 4 Close the FanMaster enclosure 5 When the Important Notice screen displays on the PanelView terminal press OK and complete the procedures in Chapter 3 FanMaster Configuration and Start Up Allen Bradley FanMaster Energy Saving Package Installation Ma
20. FanMaster Configuration and Start Up 10 11 12 13 14 15 16 17 18 19 Press the value to the right of the Supply Fan FLA field and enter the supply fan motor rated full load amps Note At this point any warning messages about an incorrect AHU unit CFM value may display and can be disregarded until all values for the supply and return fans have been entered Press OK Press the value to the right of the Unit CFM field and enter the air flow volume for the AHU If you do not know the unit CFM enter 0 in this field to allow FanMaster to provide a calculated value based on 2 000 CFM per 1 HP e g a 15 HP Supply Fan 30 000 CFM An accurate value will display in this field only after all supply fan and return fan if installed values have been entered If a return fan is not installed press No next to the Does AHU Have A Return Fan field If you pressed No for this step continue with step 15 below If a return fan is installed press the value to the right of the Return Fan HP field and enter the return fan motor rated horsepower If a return fan is installed press the value to the right of the Supply Fan FLA field and enter the supply fan motor rated full load amps Press the value to the right of the Elect Cost per kWh field and enter the appropriate electricity cost in dollars per kilowatt hour Press the value to the right of the Nat
21. FanMaster for integration with an AHU e 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 e 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 e When installing FanMaster with a Variable Frequency Drive the following firmware revisions must be used PowerFlex 400 v1 004 and later 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 e Variable speed drill e Sheet metal drill bits e Various screwdrivers e Various wrenches open s
22. Gas Cost MMBTU field and enter the appropriate natural gas cost in dollars per one million BTUs Note For HVAC systems with electric heating elements instead of gas set the value of this field to a value that is double the prevailing utility rate electric heat is typically twice the cost of gas This value will allow the calculator to estimate the cost of electric heat Press the value to the right of the Heating Efficiency field and enter the percentage of heating efficiency If not known the default value can remain however may affect the calculated energy savings results Press the value to the right of the Damper Minimum Pos field and enter the estimated outside air damper open position when not in economizer free cooling mode This is the normal fresh air ventilation position Ten percent is typical Note For systems with no outside air damper set this field to 0 This will disable any possible heating or cooling savings calculations Select the coolant type used for the AHU Press the up and down arrows Swami ag below the list to scroll to and choose a type Press Enter al to apply your selection The selected type will be highlighted Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Configuration and Start Up 3 9 20 Press Next The Setup Date and Time screen displays SETUP DATE AND TIME
23. Indicator Switch 2 12 FanMaster Control 2 12 FanMaster Power 2 11 Flow Switch 2 18 For Constant Ventilation Control 2 17 For FanMaster Fault 2 18 For High CO2 Alarm 2 18 Mixed Air Temperature Transmitter 2 12 Outside Air Damper Control 2 15 Pressure Sensor 2 18 RJ45 Adapter 2 12 Supply Air Temperature Transmitter 2 12 Supply Fan Current Switch 2 12 Wiring Diagrams B 1 WWW World Wide Web p 2 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Index 4 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 U S Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support abdrives www tockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication FANM INO01B EN P December 2009 PN 65329 Supersedes FANM INO01A EN P April 2009 Copyright 2009 Rockwell
24. Input Optional z 20 COMM H TB an CIDH SHIELD COM B A TERM D Damper Position Switch In Econ Mode TB2 Signal 24V DC Black r 1 100 Econ Mode Switch 24V DC Red 105 Input Signal for Econ Mode Switch TB2 BAS Outside Air Customer Supplied Line 119 BAS Damper Override Damper Override Control 120 f Control Output Signal Customer Selected J Line Common r Customer Supplied Nuetral Notes A 1 All power I O and signal wire is customer supplied To Sheet 2 2 Non shielded wires to be Belden No 3105A or equal 3 Shielded cable to be a Belden No 3106A or equal Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 ToS eet 2 Customer Supplied 120V AC 50 60 Hz Power Supply Air Temperature Sensor Mixed Air Temperature Sensor Carbon Dioxide Sensor BAS Start Stop 24 V or 120 V AC Run Customer Fan Proof of Running Relay Optional Customer Carbon Dioxide Alarm Horn or Beacon Optional Customer FanMaster Not Faulted Relay Optional FanMaster Diagrams B 13 Figure B 12 Interconnect Diagram Sheet 2 From Sheet 1 From Sheet 1 A FanMaster A 2 oJ M Power Supply Air Temp Sensor 24V DC Out ss Signal 4 20 mA 123 Supply Air Temp Sensor Signal Input Com 102 Supply Air Temp Sensor Common 124 Shield 3 4 lus M 102
25. N L2 N L 7 GND PLC MicroLogix 1100 ENP 1763 L16BWA Ne Port PLC1 Crossover EtherNet Cable E Net Port PanelView C600 GND too Hio2H PanelView l as el TB2 TB2 219 TB2 100 24V DC 102 0V DC To Sheet 1B To Sheet 1B Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Diagrams B 7 Figure B 6 FanMaster Evaluation Unit Schematic Diagram Sheet 1B MicroLogix 1100 From Sheet 1A Base IO From Sheet 1A A Slot 0 A 100 24V DC DUE 102 0V DC DC Com 102 1 0 TB2 TB2 n Signal I 105 Line Damper in Econ Mode Switch 105 1 2 1 3 102 TB2 TB2 5 Hne Fan Motor Running see 109 pe Current Switch boa 6 102 IA Com M1 V2 Outputs VAC VDC 0 0 VAC VDC on VAC VDC x 116 0 2 VAC x VDC 0 3 VAC VDC 0 4 VAC VDC 0 5 5 FanMaster Fault 100 24V DC 102 0V DC To Sheet 2A To Sheet 2A Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 B 8 FanMaster Diagrams Figure B 7 FanMaster Evaluation Unit Schemati
26. Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 3 24 FanMaster Configuration and Start Up 55 When the test is complete press OK and then Next The Data Collection screen displays Data Collection DONE 56 In order to finalize the configuration you will clear any data currently stored in the logs and then put FanMaster into service collecting new data Press Clear Logs on the Data Collection screen A message displays to confirm that you want to delete the data stored in the log Press Yes 57 Press Start Collecting Stopped will change to Collecting FanMaster can run permanently and will collect and store up to five years of data After five years the oldest data will be overwritten by new data on a month by month basis 58 Press Done The Air Handler Unit Diagram screen displays TYPICAL AHU DIAGRAM C02 ppm Fee MAT CF SAT CF 72 59 Confirm that there are no error messages displayed on the screen If any alarms or error messages display refer to Chapter 4 Troubleshooting for more information Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Configuration and Start Up 3 25 60 Verify that the temperature transmitters and CO sensor readings are acceptable Insert a calibrated thermometer
27. Red J 105 Input Signal for Econ Mode Switch TB2 BAS Outside Air Customer Supplied Line 119 _ BAS Damper Override Damper Override Control 120 I f Control Output Signal Customer Selected Line Common ur Customer Supplied Nuetral 2 z 1 All power I O and signal wire is customer supplied To Sheet 2 To Sheet 2 2 Non shielded wires to be Belden No 3105A or equal 3 Shielded cable to be a Belden No 3106A or equal Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 B 12 FanMaster Diagrams Optional Position Figure B 11 Interconnect Diagram for PowerFlex 753 Drive Sheet 1 PowerFlex 753 FanMaster Drive TB2 TB2 I i Rono 135 Drive Running Roc Signal 120V AC i Fan Running Input Supply Fan Drive 20 COMM H TB TB3 GND RS 485 cable CGND SHED Command to Damper SHIELD A A SHLD COM TT TT COM Signal 4 20 mA Drive TB1 LI LI i N alaei B ISI MI B k L L LL lt J U L Ao0 AO 0c A lt C adie TERM TERM T PH ae Installed Jumpers PowerFlex 753 Signal RS 485 TB1 Return Fan Drive 120V AC
28. Supply Air Low Limit 45 Supply Air High Limit 4 4 FACTO ONLY RADIE 6 Press PNLVW CONFIG The PanelView screen displays Loading for a short time and then the Main configuration screen displays Main Current Application File Manager Fantastrv114 Goto communication Configuration Language nglish Startup Application Portugu s Fran ais Display Italiano Deutsch Espa ol r 0 Date and Time tem Information Reset Terminal Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Application Firmware Upgrades D 5 7 Press File Manager on the left side of the screen The File Manager screen displays Main File Manager File Manager Source A Internal Communication aranMastry 113 Startup Application Initial T6C Display ate and Time System Information 8 Press the down arrow next to Source until USB displays Main File Manager File Manager Source Communication FariMastrv 200 Startup Application Display ate and Time System Information Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 D 6 FanMaster Application Firmware Upgrades 9 Select the file in the list that has the new Panel View application firmware and press Copy below the list The Copy File sc
29. 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 sensor and the fan 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 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 1 6 FanMaster Overview FanMaster Application Considerations 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
30. 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 INO01B EN P December 2009 PN 65329 1 4 FanMaster Overview FanMaster Operation 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 existin
31. device e Check the transmitter probe and wiring for damage and replace if necessary e Check for loose wiring at the transmitter or at terminal block 2 in the FanMaster unit e f an OOR still exists replace the transmitter Mixed Air Temperature Out Of Range One of the following has occurred e The polarity of the device wiring is incorrect e Verify that the wiring is correct e The mixed air temperature is above or below the operating range OOR of the device e Check the transmitter probe and wiring for damage and replace if necessary e Check for loose wiring at the transmitter or at terminal block 2 in the FanMaster unit e lf an OOR still exists replace the transmitter CO2 Level Out Of Range One of the following has occurred e The polarity of the device wiring is incorrect Verify that the wiring is correct e The CO level is above or below the operating range OOR of the device e Check the sensor probe and wiring for damage and replace if necessary e Check for loose wiring at the sensor or at terminal block 2 in the FanMaster unit e f an OOR still exists replace the sensor Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Alarm Pressure Out Of Range Description One of the following has occurred Troubleshooting 4 3 Possible Action s e The polarity of the device
32. in the corresponding VFD Output Min field when heating the conditioned space For two state heating When the difference in temperature rises above the value set in this field the supply fan will be commanded to full speed 100 on For proportional heating When the difference in temperature rises above the value set in this field the supply fan will ramp up to a speed proportionate to the temperature difference Press the value next to Delta T Max and enter the difference in temperature between the mixed air and supply air at or above which the drive will run the supply fan at the maximum speed set in the corresponding VFD Output Max field when heating the conditioned space For two state heating The value set in this field has no affect on the fan motor speed and can be left set to the default value For proportional heating When the difference in temperature is below the value in this field the supply fan will ramp up to a speed proportionate to the temperature difference until the value in this field is reached Once the temperature difference in this field is reached the fan speed will not exceed the value set in the corresponding VFD Output Max field typically 100 Press the value next to VFD Output Min and enter the percentage of full speed that the drive will run the supply fan when the temperature difference is at or below the minimum value set in the corresponding De
33. into the air duct where the mixed air temperature transmitter is installed and compare the reading to the value displayed in the MAT F field on the Air Handler Unit Diagram screen The value in the MAT F field should be within 5 of the of the value on the thermometer Insert a calibrated thermometer into the air duct where the supply air temperature transmitter is installed and compare the reading to the value displayed in the SAT F field on the Air Handler Unit Diagram screen The value in the SAT F field should be within 5 of the of the value on the thermometer Insert a calibrated carbon dioxide sensor into the air duct where the CO sensor is installed and compare the reading to the value displayed in the CO2 ppm field on the Air Handler Unit Diagram screen The value in the CO2 ppm field should be within 5 of the of the value on the sensor Note When the AHU cooling and heating elements are off but the supply fan is running the mixed air and supply air temperatures should typically be within a few degrees of each other indicating proper calibration and operation Important All instruments are calibrated at the factory Follow the manufacturer s recommended calibration practices in order to maintain the accuracy of the instruments You have successfully installed and configured the Allen Bradley FanMaster Energy Saving Package If you wan
34. mm and inches L 610 00 J 24 00 19 00 572 00 l 291 00 E 075 22 50 11 47 231 00 Clearance for 9 5 3 8 9 10 18 00 Mounting Hardware 0 72 Typ 4 Places 203 00 8 00 T g lo I r 646 00 25 45 673 00 610 00 26 50 24 00 Allen Bradley amp 9 FanMaster o o Side View Bottom View Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 2 10 FanMaster Installation FanMaster Enclosure Weights Enclosure Enclosure Only Enclosure and Packaging NEMA UL Type 1 21 0kg 46 lb 26 3 kg 58 Ib NEMA UL Type 4 136 3 kg 80 lb 41 7 kg 92 Ib 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 A equipment damage e Inspect all lifting hardware for proper attachment before lifting the enclosure e Do Not allow any part of the enclosure or lifting mechanism to make contact with electrically charged conductors or compone
35. screen is used to set the supply fan parameters in the drive to the correct values PowerFlex 400 70EC and 700VC Drives SUPPLY FAN SETUP Step 1 Power Up Supply Fan WFO Set HOAto OFF Af installed Power Down Retum Fan VF DG installed It using PFFOEC or PFPOO WC set Comm Parameters per Fanhgeter Installation bianual For all diwes press Set eae Supply Fan Defaults then Power Down Supply Fan VF D Step 2 Power Up Supply Fan WFO Set HOAto OFF Cif installed Power Down Retum Fan if installed Press Set Supply Fan Params NEXT PowerFlex 753 Drives Only SUPPLY FAN SETUP Step 1 Power Up Supply Fan VFO Power Down Retum Fan WF Dit installed Set Supply Fan parameters to defaults per Fanhtaster installation manual Power Supply Fan WFD fully off then back on Set additional parameters per Fanhaster installation manual Power Supply Fan VFO fully off then back on Step 2 Power Up Supply Fan VFO Set HOAto OFF t installed Power Down Retum Fan it installed Press Set Supply Fan Params Table C G Supply Fan Setup Screen Fields Field Name Description Step 1 Set Supply Fan Used to set the supply fan to the default values Defaults Step 2 Set Supply Fan Used to set the supply fan parameter values Params AHU Press to view the Air Handler Unit Diagram Screen Back Press to view the Setup Screen 3 Next Press to view the Return Fan Setup Screen or Fan C
36. 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 FanMaster Installation 2 5 Damper Position Indicator Switch e If your installation does not use constant ventilation install the damper 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 e Ifyou are installing an evaluation unit only clamp the current switch around any one of the supply fan motor leads 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 N
37. the month Set Year Current year Set Hour Current hour military format Set Minute Current minute date and time Displays the time entered in the time and date fields Press to Accept Press to accept your entries and set the current date and time AHU Press to view the Air Handler Unit Diagram Screen Back Press to view the Setup Screen 1 Next Press to view the Setup Screen 2 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 C 6 FanMaster Screens and Field Descriptions Setup Screen 2 The second Setup screen is used to enter data required to configure the FanMaster for your installation This screen is different for evaluation unit versus units installed with a drive This configuration is completed at the factory Evaluation Unit Install Only HEATING PROP Permanent Install Only PF400 PF70E PF75 HEATING PROP PF70050 NEXT Table C E Setup Screen 2 Fields Field Name Drive Type Description Type of drive installed Choose the drive installed using the up or down and Enter arrow buttons No selections are available for evaluation units Heating Prop Proportional Heating Prop or two state Heating 2 State heating system selection Cooling Prop Proportional Cooling Prop or two state Cooling 2 State cooling sys
38. wiring is incorrect e Verify that the wiring is correct e The pressure hose is crimped or blocked e Check for a damaged or block pressure hose e The pressure level is above or below the operating range OOR of the device e Check the pressure sensor wiring for damage and replace if necessary e Check for loose wiring at the sensor or at terminal block 2 in the FanMaster unit e fan OOR still exists replace the sensor Return Fan Comm Fault One of the following has occurred e The polarity of the device wiring is incorrect e Verify that the wiring is correct e Acommunication loss has occurred between the return air fan drive and the FanMaster e Verify that the drive is energized e Check for a loose or damaged communication cable Return Fan Drive Fault A return air fan drive fault has occurred e View the drive HIM display to identify the fault code and refer to the Troubleshooting section of the PowerFlex 400 AC Drive for Fan amp Pump Applications User Manual publication 22C UM001 for more information Supply Fan Comm Fault One of the following has occurred e The polarity of the device wiring is incorrect Verify that the wiring is correct e Acommunication loss has occurred between the supply air fan drive and the FanMaster Verify that the drive is energized e Check for a loose or damaged communication cable Supply Fan Drive Fault A su
39. 001B EN P December 2009 PN 65329 FanMaster Configuration and Start Up 3 11 29 If the AHU uses a proportional heating system heating source level is varied continue with the next step If the AHU uses a two state heating is on or off heating system press Heating Prop so that Heating 2 State displays 30 If the AHU uses a proportional cooling system cooling source level is varied continue with the next step If the AHU uses a two state cooling is on or off cooling system press Cooling Prop so that Cooling 2 State displays 31 If a pressure sensor is not used continue with the next step If a pressure sensor is used press No Pressure so that Pressure displays Note A pressure sensor must be installed and configured as an analog input to FanMaster 32 If the AHU runs in demand ventilation mode used in combination with a CO sensor to provide on demand ventilation to maintain the appropriate CO level in the conditioned space continue with the next step If the AHU runs in constant ventilation mode press Demand Vent so that Constant Vent displays if a pressure sensor is installed constant ventilation mode cannot be used Note Demand ventilation reduces the cost associated with cooling and heating excessive outside air flows Constant ventilation does not reduce the cost associated with cooling and heating outside air flows and is therefore only recommended for
40. 3 1 Example Two State Cooling Setup Two State Cooling Setup Delta T Delta T Min Max VFD 100 Output gt Max of g 75 O VFD c 50 Output Min 25 u L u L L 0 10 20 30 40 50 Delta T Mixed Air Supply Air Temp Figure 3 2 Example Proportional Cooling Setup Proportional Cooling Delta T Delta T Min Max VFD 100 Output Max 75 D VFD Z 50 Output Min LL 25 t I u t I 0 10 20 30 40 50 Delta T Mixed Air Supply Air Temp Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 3 20 FanMaster Configuration and Start Up 49 Below Cooling Setup enter the following values a Press the value next to Delta T Min and enter the difference in temperature between the mixed air and supply air at or below which the drive will run the supply fan at the minimum speed set in the corresponding VFD Output Min field when cooling the conditioned space For two state cooling When the difference in temperature rises above the value set in this field the supply fan will be commanded to full speed 100 on For proportional cooling When the difference in temperature rises above the value set in this field the supply fan will ramp up to a speed proportionate to the temperature difference Press the value next to Delta T Max and enter the diff
41. 400 drives complete the tasks on the Supply Fan Setup screen only For PowerFlex 70EC 700VC or 753 drives complete the tasks on the screen and the appropriate steps detailed on the following pages only when instructed to do so Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 3 14 FanMaster Configuration and Start Up Important If after completing the steps below the following alarm message displays Drive Parameter Write Failed do the following Verify all communication wiring between the drive s and FanMaster Verify the parameter settings for PowerFlex 70EC 700VC or 753 drives as instructed below Setting the Parameters in a PowerFlex 70EC or 700VC Drive below Setting the Parameters in a PowerFlex 753 Drive on page 3 15 Setting the Parameters in a PowerFlex 70EC or 700VC Drive Important When removing power from the drive s as directed in the steps on this screen verify that the drive is fully de energized by waiting until the HIM module LED display is off a Press the ESC key Esc until the Main Menu displays as shown below Main Menu Diagnostics Parameter Device Select b Press the Down arrow key to select Device Select c Press the Enter key d Press the Down arrow key twice to select 20 COMM H in the list e Press the Enter key f Press
42. 400 terminal 8 Verify that the switch contact closes when Auto is selected Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 2 18 FanMaster Installation 21 22 23 24 25 26 27 28 Optional If a dry contact output from FanMaster that closes on a high CO level is required for connection to a BAS CO alarm device connect the signal wires from the CO alarm annunciation device to terminals 117 and 118 on TB2 in the FanMaster enclosure Optional If a dry contact output from FanMaster that opens when FanMaster faults is required for connection to a BAS annunciation device connect the signal wires from to the annunciation device to terminals 121 and 122 on TB2 in the FanMaster enclosure Optional If your AHU currently utilizes a flow switch or pressure sensor and requires a proof of flow dry contact output from FanMaster connect the signal wires from the contact to terminals 100 102 218 and 219 on TB2 in the FanMaster enclosure A heater is included in the FanMaster NEMA UL Type 4 enclosure to allow for maintaining the proper temperatures for the equipment in the enclosure Use the adjustment knob on the heater unit to set the temperature to about 5 C 40 F Apply power to FanMaster by setting CB1 in the FanMaster enclosure to the on position Close and secure the cover on the FanMaster enclosure Replace or c
43. 5329 2 14 FanMaster Installation 10 11 12 13 Connect the normally open Run contact in the supply fan drive to FanMaster to indicate that the supply fan motor is running For PowerFlex 400 drives connect terminal R4 on the drive relay TB to terminal 135 on TB2 in FanMaster and terminal R5 on the drive relay TB to terminal N on TB2 in FanMaster Note The relay terminal block is on the front of the drive below the communication adapter For PowerFlex 70EC drives connect terminal 24 on the drive I O TB to terminal 135 on TB2 in FanMaster and terminal 25 on the drive I O TB to terminal N on TB2 in FanMaster Note The I O terminal block is on the front of the drive below the communication adapter For PowerFlex 700VC drives connect terminal 16 on the drive I O TB to terminal 135 on TB2 in FanMaster and terminal 15 on the drive I O TB to terminal N on TB2 in FanMaster Note The I O terminal block is on the front of the drive to the left of the communication adapter For PowerFlex 753 drives connect terminal RONO on the drive Relay TB2 on the Main Control board to terminal 135 on TB2 in FanMaster and terminal ROC on the drive Relay TB2 to terminal N on TB2 in FanMaster Note The relay terminal block TB2 is on the bottom back edge of the main control board Remove the three phase AC line supply side from the existing fan motor starter contactor and reconnect to the drive line terminals
44. 6s cel 001 28 001 091 091 zaL g i 0 1015 114 601 601 281 601 1 t8l 181 sei car A SSL i tal ia cist is zal ofofo plea Oh LO Oji Ol O F3 9s1 al 961 z 2S ZeL asi car A 85 Sial ISL Sr Zal 9h Lyl Zal IL spi zal A chi poms OTOOTO Tey lololol 5 8b l cel Br ef IE osi za A SL 6ri zal A 6l 0 i 0 1015 1914 01 se 2v 240 001 2al 001 poet sel za OI CIT T Ts OTTO eloh O LO OJ O S Ovl Zal Oi z Zy1 281 A Ztl ti 28 A It i ee ioe Sy momen 1e z0 2al z0l 8 29 101 lsd 0 CB2 001 001 zaL z z Z 2 HOO z S zzl 33 Sg ab oOo FE rt t ica kapag s E L am l ae Si a p t a 2 T gg Wl t al s AS 01 01 Z81 g gt BR 611 61 1 ZaL z J S lial 1 2 Pk A e 1e 60 g lsg EN a S 9 ix ley 001 001 zaL 2 s dha s 1ss 901 2 a gz Sh eli a so1 zal SOL s E S ooon a lsg E pu 1180 s01 ng go z z Ges wa zoi _ 8 2 325 So 8 Bfm 8 Ei N N lab s g og C 1804 13N3 140d 835
45. Alarm Setpoint ppm and enter the CO parts per million ppm at which the an alarm will display on the Panel View screen the fault indicator lamp on the front of the unit will turn on and the FanMaster Faulted signal will be set to Faulted indicating that the high CO level threshold has been exceeded 42 Press Next The Supply Fan Setup screen displays SUPPLY FAN SETUP Step 1 Power Up Supply Fan WFD Set HOAto OFF cit installed Power Down Retum Fan WF Dit installed It using PFFOEC or PF70037 set Comm Parameters per Fanhigeter Installation bianual For all diwes press Set aed Supply Fan Defaults then Power Down Supply Fan WFO Step 2 Power Up Supply Fan VFO Set HOAto OFF fit installed Power Down Retum Fan if installed Press Set Supply Fan Params PowerFlex 753 Drives Only SUPPLY FAN SETUP Step 1 Power Up Supply Fan VFO Power Down Retum Fan WF Dit installed Set Supply Fan parameters to defaults per Fanhtaster installation manual Power Supply Fan WFD fully off then back on Set additional parameters per Fanhaster installation manual Power Supply Fan FD fully off then back on Step 2 Power Up Supply Fan VFO Set HOAto OFF iit installed Power Down Retum Fan it installed Press Set Supply Fan Params 43 Read and complete the tasks in steps 1 and 2 on the Supply Fan Setup screen to set the supply fan drive parameters to the correct values NEXT NEAT For PowerFlex
46. Automation Inc All rights reserved Printed in USA
47. EMA 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 TBI 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 7OEC 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 INO01B EN P December 2009 PN 65329 2 6 FanMaster Installation This publication provides specific steps for interconnecting the drive and Fa
48. Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Configuration and Start Up 3 5 3 Read the notes on the screen and press OK The Dashboard screen displays FanMaster 0 D Allen Bradley ea v2 00 4 Press Next The Air Handler Unit Diagram screen displays TYPICAL AHU DIAGRAM cO ppm Fe MAT CSF SAT OFS DASH AOARO Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 3 6 FanMaster Configuration and Start Up 5 6 7 Press Setup You are prompted to enter a user name and password gt at Press in the User field and using the keypad type s Press in the Password field and using the keypad type 258 and press Enter l The first Setup screen displays Note If the PanelView is inactive for more than 15 minutes you will be logged out and returned to a non secured screen When you press Setup again you be required to log back into the setup screens Elect Cost per kwh SRD t i Nat Gas Cost SMMBTL OE a COL or WATER Does AHU Hawe eo FREON ARetum Fan S a Return Fan HP 5 0 Return FanFLa EE Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 P
49. FanMaster Energy Saving Package Allen Bradley Installation Manual v2 xx Allen Bradley Rockwell Software Automation 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_http 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 Reprod
50. I Reno Cannon Intl NV Birmingham AL El Paso TX Medford Jackson Co OR Roanoke VA Boise ID Eugene Mahlon Sweet Fld OR Memphis TN Rock Springs WY Boston Logan MA Fort Worth NAS TX Miami FL Salt Lake City UT Brownsville TX Fresno CA Midland TX San Francisco CA Buffalo NY Glasgow MT Minneapolis St Paul MN Scottsbluff NE Burlington VT Hartford Bradley CT Minot AFB ND Seattle Boeing Field WA Charleston SC Honolulu Oahu HI Missoula Bell Field MT Spokane WA Charleston Kanawha WV Houston Intercont TX New Orleans Intern LA Springfield MO Chattanooga Lovell TN Indianapolis IN New York John F Kennedy NY St Louis Lambert MO Chicago O Hare IL Jacksonville FL N Platte Lee Bird NE Syracuse Hancock NY Columbia SC Jackson Thompson MS Oklahoma City OK Tucumcari NM Cut Bank MT Knoxville TN Pendleton OR Washington Dulles VA Dayton James M Cox OH Lander Hunt WY Philadelphia PA Winslow AZ Denver Stapleton CO Las Vegas McCarran Intl NV Phoenix Sky Harbor AZ North America Canada City City City City Calgary Halifax St John s Vancouver Churchill Montreal Saskatoon Winnipeg Edmonton Ottawa Thunder Bay Gander Prince George Toronto Pearson Europe City Country Berlin Germany London England Central and South America City Country Mexico City Mexico Rio De Jeneiro Brazil Sa
51. MA UL Type 4 enclosures drill the desired openings in the enclosure to accommodate conduit connections 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 A ATTENTION Protect the contents of the enclosure from metal 2 Open the FanMaster enclosure and verify that circuit breaker 1 CB1 is in the off position D eon Allen Bradley Pay o FanMaster NEMA UL Type 1 Enclosure Shown 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 INO01B 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 for control wire size 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 Wire the mixed air temperature transmitter according to the manufactur
52. Mixed Air Temp Sensor Common 126 Shield Power 100 Mixed Air Temp Sensor 24V DC Out J Signal 4 20mA 125 Mixed Air Temp Sensor Signal Input 3 4 w Po A S Power Carbon Dioxide Sensor 24V DC Out j Signal 4 20 mA 127 Carbon Dioxide Sensor Signal Input Com 102 Carbon Dioxide Sensor Common 128 Shield TB2 __ Signal 24V or 120V AC Q CR4 gt BAS Start Fan Command Input 7 TB2 Customer Supplied une HH Fan Proof of Running Output 114 14 Line Signal Customer Selected J Com t Customer Supplied Neutral TB2 Customer Supplied Line PP High Carbon Dioxide Alarm Output i Signal Customer Selected Line Com Customer Supplied Neutral TB2 Customer Supplied Line 121 PP 122 FanMaster Not Faulted Output A Signal Customer Selected J Line Com Customer Supplied Neutral 1 CR4 in FanMaster to be 700 HK32A24 for 24V AC or 700 HK32A1 for 120V AC BAS Start Signal Note All Power I O and signal wire is customer supplied To Sheet 3 To Sheet 3 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 B 14 FanMaster Diagrams Figure B 13 Interconnect Diagram Sheet 3 From Sheet 2 B FanMaster 7 TB2 Pressure
53. N 65329 FanMaster Configuration and Start Up 3 7 8 Select the city with the climate profile closest to the installation location refer to City Climate Profiles on page A 3 for a list of city values Press the up and down arrows EFWE below the list to scroll to and choose a city City names are listed alphabetically in order of North America U S then Canada Europe Central and South America and Asia Press Enter al to apply your selection The selected city will be highlighted If an acceptable climate profile is not included in the list press User City to access the User City Weather Data Setup screen described on page C 14 where you can create and save a climate profile for your location You must enter weather data as described in City Climate Data on page 1 9 9 Press the value to the right of the Supply Fan HP field and enter the supply fan motor rated horsepower When a value field is pressed a numeric keypad displays and the value is editable Use the keypad to type the desired value and press Enter to accept the value For fields with a decimal value you must enter the desired value for the field including the decimal value For example For a value of 10 0 press 1 0 0 Press Esc to exit edit mode and cancel any edits Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 3 8
54. Press to view the Air Handler Unit Diagram Screen Back Press to view the Cooling and Heating Setup Screen Next Press to view the Data Collection Screen Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Screens and Field Descriptions C 13 Data Collection Screen The Data Collection screen is used to start and stop data collection and or clear the data logs Data Collection DONE Table C L Data Collection Screen Fields Field Name Start Stop Collecting Description Starts or stops data logging When Start Collecting is pressed Stopped changes to Collecting When Stop Collecting is pressed Collecting changes to Stopped Clear Logs Deletes all data currently stored in the data log AHU Press to view the Air Handler Unit Diagram Screen Back Press to view the Proof of Flow Setup Screen Note Back does not display when this screen is accessed from the Data Log 1 Screen Done Press to view the Air Handler Unit Diagram Screen Note Done does not display when this screen is accessed from the Data Log 1 Screen Data Log Press to return to the Data Log 1 Screen Note Data Log does not display when this screen is accessed from the Proof of Flow Screen Allen Bradley FanMaster Energy Saving Package Installation Manual P
55. Sensor Power 00 Sensor 24V DC Optional t m Signal 4 20 mA C Me Sensor Signal Input Com 02 Sensor Ground n 219 Shield OR TB2 sif fal 00 Sensor 24V DC Damper Position FP a E Sensor Signal Input Command from BAS Out Signal 4 20 mA Y I 102 Sensor Ground Optional 219 shield TB2 m H N 40 1 The optional pressure sensor and damper position command from BAS inputs are mutually exclusive only one can be used 2 The FanMaster input for the optional damper postion command from the BAS is not isolated As isolator may need to be added by the customer if the application requires isolation Note All power I O and signal wire is customer supplied 142 TB2 145 147 146 Spare Fan Running Auxiliary Contacts for Customer Use E TB2 149 148 150 E TB2 e 151 152 154 157 156 158 153 155 A2 Ocr3 Al Spare for Customer Use E TB2 161 a 162 Spare BAS Run Auxiliary Contact for Customer Use From Sheet 2 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Figure B 14 Wiring Diagram FanMaster z91 2al _ 291 191 281 19h 8s g
56. The difference in temperature between the mixed air and supply air at or below which the drive will run the supply fan at the minimum speed when cooling the conditioned space 49b The difference in temperature between the mixed air and supply air at or above which the 25 drive will run the supply fan at the maximum speed when cooling the conditioned space 49c The percentage of full speed that the drive will run the supply fan when the temperature 50 difference is at or below the minimum value when cooling the conditioned space Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Configuration and Start Up 3 3 Step Data Required Default Value Actual 49d The percentage of full speed that the drive will run the supply fan when the temperature 100 difference is at or above the maximum value when cooling the conditioned space 49a The difference in temperature between the mixed air and supply air at or below which the 5 drive will run the supply fan at the minimum speed when heating the conditioned space 50b The difference in temperature between the mixed air and supply air at or above which the 50 drive will run the supply fan at the maximum speed when heating the conditioned space 50c The percentage of full speed that the drive will run the supply fan when the temperature 50 difference is at or below the minimu
57. Up 3 21 Note When in heating mode the supply fan speed will typically be set based on the difference in temperature Delta T between the mixed air and supply air as illustrated using default values in Figure 3 3 and Figure 3 4 below unless the supply air temperature exceeds the high limit override is greater than the default value of 155 F If the supply air temperature exceeds the high limit override value the fan speed will increase to the VFD output maximum value for heating setup Figure 3 3 Example Two State Heating Setup Two State Heating Setup Delta T Delta T Min Max VFD 100 Output lt Max o 75 oO VFD c 50 Output Min 25 u L u L 0 10 20 30 40 50 Delta T Supply Air Mixed Air Temp Figure3 4 Example Proportional Heating Setup Proportional Heating Delta T Delta T Min Max VFD 100 Output Max xe D VFD 50 Output Min LL 25 T u t u t 0 10 20 0 40 50 Delta T Supply Air Mixed Air Temp Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 3 22 FanMaster Configuration and Start Up 50 Below Heating Setup enter the following values a Press the value next to Delta T Min and enter the difference in temperature between the mixed air and supply air at or below which the drive will run the supply fan at the minimum speed set
58. Wd OL 0 3 180 dl z FanMaster Diagrams lt om 7N Z N a gt x lt Ez WO os 9 1 Urug ae ee a oO E l Zol 01 81 gt 5 OVA 180 12 t l ius N 612 8L I 5 L a we 00l 5 lt 00 001 zaL s a 9 lH 09 Isd 09 5 Z1 28l 0N9 5 Aasen e eam e OT TO P 0N9 1Sd zzz QNO zza O SL I OO O o O wN q m yood DN Ee ra 155 Q Ge s ae a gs s N 45 o g m sz m gy 85 ES ss 58 N i N N T ISsda Q N lMIH N 3 N w CI N Tu y O llo 191 194 O i W0 9l Z9L O N 49 est 7 6S4 O W449 091 09L E 92 24 isi z st oO 22 49 891 gt gst O ZL EY9 ssl SSL O 2 249 961 9st oO lg esl gst O vL 49 v1 T L re ZN EY9 ISL ist oO W 49 zs gt ZSL oO 92 780 61 gt 6tl oO 22 249 0S1 gt Ost O 21 289 a del e
59. age B 3 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 4 2 Troubleshooting FanMaster Alarms Alarm Supply Air Temperature Out Of Range An alarm banner displays on the PanelView terminal to indicate an alarm condition The alarm banner displays on the screen until Ack Acknowledge is pressed Clearing the alarm banner does not remove the alarm condition Refer to the table below for a complete list of alarms and possible actions Note If after investigation sensor problems persist you may switch FanMaster to override mode by setting the FanMaster Override switch on the front of the FanMaster enclosure to ON This allows FanMaster to run at 100 speed whenever the original HVAC controls call for the fan to run FanMaster Faulted Light FanMaster Override Switch Allen Bradley PanelView C600 FANMASTER FAULTED Also If the drive has faulted and the fault cannot be cleared and if the installed drive is equipped with a bypass switch it can be used to bypass the drive and use a bypass starter to run the fan Table 4 4 FanMaster Alarms Description One of the following has occurred Possible Action s e The polarity of the device wiring is incorrect e Verify that the wiring is correct e The supply air temperature is above or below the operating range OOR of the
60. and Off Auto switch in the Pin 8 Auto position The switch snaps into place on the second switch level on the Adapter Detail A Pin 5 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 B 10 FanMaster Diagrams Optional Position Command to Damper Signal 4 20 mA N u Interconnect Diagram for PowerFlex 70EC Drive Sheet 1 Figure B 9 PowerFlex 70EC Drive I O TB TB2 I a ETR 135 Drive Running 25 Signal 120V AC i Supply Fan Drive 20 COMM H TB TB3 GND RS 485 cable CGND SHIELD SHLD Drive I O TB a A com rive B TT TT B 23 A 0 A d d q 22 A O Com TERM CID PowerFlex 70EC Signal RS 485 Return Fan Drive Optional 20 COMM H TB end C L DH SHED com H B A TERM Do Damper Position Switch In Econ Black Red BAS Outside Air Fan Running Input Econ Mode Switch 24V DC Input Signal for Econ Mode Switch Mode TB2 Signal 24V DC 100 F C J 105 TB2 Customer Supplied Line 119 120 Damper Override Control Notes 1 All power I O and signal wire is customer supplied Signal Customer Selected Line Common Customer Supplied Nuetral
61. 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 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
62. aster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 C 12 FanMaster Screens and Field Descriptions Proof of Flow Setup Screen The Proof of Flow Setup screen is used to set the torque current level at which the drive will run the supply fan at the minimum speed The existing proof of flow sensor flow switch or pressure sensor may not provide accurate proof of flow at a reduced fan speed FanMaster will detect flow by monitoring the torque current required by the supply fan at the minimum speed If the supply fan drive is not delivering 50 of this current threshold the proof of flow output turns off This screen allows the system to capture the 50 threshold by monitoring the current supplied to the motor at the minimum fan speed This screen is also used to run the fan motor s in order to verify the proper rotation direction He 2 Tail Proof of Flow Torq Limit Percent Table C K Proof of Flow Screen Fields Field Name Description Steps 1 4 amp Auto Set Sets the minimum torque current level at which the drive will run the supply Trq Limit fan and runs drive and fan motor s for rotation direction test Proof of Flow Torg Limit The minimum torque current level required to run the supply fan motor Amps Percent This field displays the current level in percent for PowerFlex 70EC drives only All other drives current values display in Amps AHU
63. ata Collection 0 0 cee nee 3 27 Clear the Data Logs and Collect Data 0 0 0 3 28 Troubleshooting FanMaster Status u s opa ae qha dale tp hewpe dae goaded as 4 1 FanMaster Alarms 3 20 se usara passa aqa ua Si week asus hahah 4 2 Specifications and City Climate Profiles Drives and FanMaster Specifications A 1 Caty Climate Profiles cee ed bee geet Cae EAE RA ee he ee aed eee A 3 FanMaster Diagrams Drawi INdeX 5 25 eae eae S4 nao ooh as Gees ee SORES eee PEERS ERO E doe Res B 1 FanMaster Screens and Field Descriptions Dashboard Screens usss pea ia Gens wila upay ataw sedate a aha waaka C 2 Air Handler Unit Diagram Screen 0 0 eee eee eens C 3 Setup Screen Hl 7 roiie su baa eda vanes BG aeons whee tiga Susa Q Q C 4 Setup Date and Time Screen 2 0 eee cee cette nee C 5 Setup Sereen HZ jee e cieelhean ve Glee ean Pid ene Mikael oa WY ee ed es ee hes los C 6 Setup Screen 3 os occa ee ad Hee cee ee ee eS aoe bbe Ee a Serer ees C 7 Supply Fan Setup Screens wees ua aaa ha eee ea bee baa ee og eat C 8 Return Fan Setup Screen 0 0 cnc n ence nee C 9 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Appendix D Index Fan Communication Setup Screen 0 0 0 cece eee eee enna C 10 Cooling and Heating Setup Screen 00 eee eee C 10 Proof of Flow Setup Screen 0 2
64. c Diagram Sheet 2A From Sheet 1B From Sheet 1B From Sheet 1B Analog Input Expansion Module 0V DC 1762 IF4 Slot 1 Supply Air Temp Mixed Air Temp CO Sensor Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Optional Position Command to Damper FanMaster Diagrams B 9 right side of the switch as viewed from the rear Connect a wire from PF400 terminal 11 to the top of the switch Connect a wire from the bottom of the switch to PF400 terminal 8 Verify that the switch contact closes when Auto is selected Shown with 120 Ohm Terminating Resistor Figure B 8 Interconnect Diagram for PowerFlex 400 Drive Sheet 1 FanMaster Enclosure TB1 TB2 3 161 BAS Start CR4 1 Bypass Enable 36 162 A See Notes 5 and 6 PowerFlex 400 Drive TB TB2 R4 Drive Running BB Signal 120V AC Fan Running Input Supply Fan Drive AK U0 RJ45 TB2P RJ45 to TB Adapter TB3 See Note 4 Typ both Drives CGND RJ45 See adapter detail below SHLD Signal 4 20mA Drive TB RS 485 B Li con A no APS B
65. d Descriptions C 17 The third Data Log screen is used to display additional detailed monthly energy and savings data calculated by FanMaster MARCH A DA5H ROAR D k JANUARY FEBRUARY Monthly Fanbtaster Fan Speed Reduction Energy Savings Monthly Fanhtaster Speed Heating Savings wo Override Monthly Fankiaster Speed Cooling Savings wio Oweride enthhy Add l Damper Owerride Heating Cooling Savings Monthly Total Fanttaster Savings earto Date Total Fanhtaster Savings ifetime Total Fanttaster Savings e YYYY TEx ATUS Table C P Data Log 3 Screen Fields Field Name January February March Description Month selection Choose the month for which you want to view data Choose the month for which you want to view data using the up or down and Enter arrow buttons Note When the current month is selected data displayed represents the month to date values When a previous month is selected data displayed represents values for the entire month YYYY Year selection Choose the year for which you want to view data Monthly FanMaster Fan Monthly energy cost savings in dollars using FanMaster to run the AHU Speed Reduction Energy fan s at a reduced speed Savings Monthly FanMaster Monthly heating cost savings in dollars using FanMaster to run the AHU Speed Heating Savings fan s at a reduced speed without the outside air damper override w o Override Monthly FanMas
66. de of the BAS control Yes or no override of the BAS Damper Override for control No of the outside air damper selection Additional Savings Override Duty Cycle Percent of time the outside air damper will be closed during a 20 minute cycle time when FanMaster is allowed to override Valid values are 10 50 10 2 min closed 18 min open 50 10 min closed 10 min open Pressure Low Limit inwC Inches in Water Column value below which FanMaster will command the Supply Fan speed to increase in order to maintain positive pressure in the conditioned space CO2 Demand Setpoint CO parts per million ppm at which full fan speed and full outside air ppm ventilation occurs until the CO level is 50 ppm below the value set in this field CO2 Alarm Setpoint ppm CO parts per million ppm at which the an alarm will display on the PanelView screen the fault indicator lamp on the front of the unit will turn on and the FanMaster Faulted signal will be set to Faulted indicating that the high CO level threshold has been exceeded AHU Press to view the Air Handler Unit Diagram Screen Back Press to view the Setup Screen 2 Next Press to view the Supply Fan Setup Screen Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 C 8 FanMaster Screens and Field Descriptions Supply Fan Setup Screen The Supply Fan Setup
67. e Sheet 7 B 9 Figure B 9 Interconnect Diagram for PowerFlex 70EC Drive Sheet 1 B 10 Figure B 10 Interconnect Diagram for PowerFlex 700VC Drive Sheet1 B 11 Figure B 11 Interconnect Diagram for PowerFlex 753 Drive Sheet 1 B 12 Figure B 12 Interconnect Diagram Sheet 2 B 13 Figure B 13 Interconnect Diagram Sheet 3 B 14 Wiring rawing age igure B 14 Wiring Diagram FanMaster B 19 Component Layout rawing age Figure B 15 FanMaster ype 1 Enclosure Layout 16 Figure B 16 FanMaster NEMA UL Type 4 Enclosure Layout B 17 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 B 2 FanMaster Diagrams Figure B 1 CB1 TB1 L Customer s Incoming _N 120V AC 60 Hz 1 Phase Power FanMaster w Drive Schematic Diagram Sheet 1A Power Supply 120V AC In 24V DC Out a 1606 XLE120E PS1 24V DC 100 T 101 F 0V DC 102 5A 24V DC Heater Enclosure Heater NEMA UL I Type 4 Only i 1 L el N LOIN To Sheet 2B 7 GND PLC MicroLogix 1100 kas 1763 L16BWA Serial E Net PLC1 To Sheet 2B ee Port Port TB3
68. e Materials on page p 2 for 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 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 INO01B 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 amp Pump Applications Installation 22C IN002 Manual PowerFlex 400 Adjustable Frequency AC Drive for Fan amp Pump Applications User 22C UM001 Manual PowerFlex 70 Adjustable Frequency AC Drive Installation Instructions 20A IN009 PowerFlex 70 AC Drives User Ma
69. eee eee eens C 12 Data Collection Screen 0 2 ete nnn assasi ss C 13 User City Weather Data Setup Screen 1 0 eee eee C 14 Data Log 1 Scree sc cresen soe paqana qua s a ide a nde waa ee C 15 Data Log 2 SCreen sc p0s sawasqa guile dees Oe eben dae ees C 16 Data Loe 3 Screen uuu eta ahd alah bia bide aden a EEE ade es C 17 System Status Screen eerie endian ee eae ed eae oe a Aa ee a he C 18 FanMaster Application Firmware Upgrades Required Equipment 00 0 cece ccc eaae erare 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 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Who Should Use This Manual What is Contained in this Manual Manual Conventions Preface General Information 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 Referenc
70. ency for your system 87 18 Outside air damper minimum open position 10 19 Coolant type used Glycol or Water 29 Is heating proportional heat source level is varied or two state heating is on or off Heating Prop 30 Is cooling proportional cooling source level is varied or two state cooling is on or off Cooling Prop 31 The system uses a pressure sensor yes no No Pressure 32 The system uses on demand ventilation CO sensor is installed or constant ventilation Demand Vent Constant Vent 33 The system uses a CO sensor yes no CO2 yes 35 The AHU has a heating system yes no Yes Mech Heat 36 The AHU has a cooling system yes no Yes Mech Cool 37 FanMaster will be allowed to override the BAS control of the outside air damper yes no Yes Damper Override 38 If FanMaster will override the BAS control of the outside air damper the percent 10 50 of 50 time the outside air damper will be closed during a 20 minute cycle time 10 2 minutes closed 18 minutes open 50 10 minutes closed 10 minutes open 39 If a pressure sensor is used the inWC value below which the supply fan speed should 0 010 increase so pressure is maintained 40 If a CO sensor is installed the CO parts per million ppm at which outside air ventilation 700 should occur 41 Ifa CO sensor is installed the CO parts per million ppm at which a high CO alarm will 800 occur Sz 49a
71. er 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 Wire the CO sensor according to the manufacturer s instructions route through the appropriate conduit if used and connect the control wires to terminals 100 102 127 and 128 on TB2 in the FanMaster enclosure 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 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 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 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 no
72. er 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 level indicates the need for maximum ventilation 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 INO01B EN P December 2009 PN 65329 1 2 FanMaster Overview FanMaster Externally Temperature Sensors Mounted Components 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 A
73. ercentage of full speed if installed and configured MAT F Current mixed air temperature SAT F Current supply air temperature ECON Damper status Econ indicates that the AHU is in economizer mode Min indicates that the outside air damper is currently at the minimum open position xx indicates the percent open position only displays if the constant ventilation option is used Supply Fan Current percentage of full speed of the supply fan Dashboard Press to access the Dashboard Screen AHU Screen you are currently viewing System Status Press to view the System Status Screen Data Log Press to view the first Data Log 1 Screen Setup Press to view the first Setup Screen 1 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 C 4 FanMaster Screens and Field Descriptions Setup Screen 1 The first Setup screen is used to enter data required to configure the FanMaster for your installation So a Does AHU Have oe N FREON A Return Fan ai Return Fan HP s0 Return Fan FLA P i hat Gas Cost SMMBTLU Heating Efficiency Suppy Fan HP 40 Damper Minimum Pos Suppy Fan FLA 16 HIA OL or WATER NO 1 6 Table C C Setup Screen 1 Fields Field Name City State Country Description City and State location selection Choose the city and state country usin
74. erence in temperature between the mixed air and supply air at or above which the drive will run the supply fan at the maximum speed set in the corresponding VFD Output Max field when cooling the conditioned space For two state cooling The value set in this field has no affect on the fan motor speed and can be left set to the default value For proportional cooling When the difference in temperature is below the value in this field the supply fan will ramp up to a speed proportionate to the temperature difference until the value in this field is reached Once the temperature difference in this field is reached the fan speed will not exceed the value set in the corresponding VFD Output Max field typically 100 Press the value next to VFD Output Min and enter the percentage of full speed that the drive will run the supply fan when the temperature difference is at or below the minimum value set in the corresponding Delta T Min field when cooling the conditioned space Press the value next to VFD Output Max and enter the percentage of full speed that the drive will run the supply fan when the temperature difference is at or above the maximum value set in the corresponding Delta T Max field when cooling the conditioned space Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Configuration and Start
75. etup screen displays FAN COMMUNICATION SETUP Results Set HOACS3to Auto if installed Step 5 Power Up Retum Fan WFO and Power Up Supply Fan Press Test WFO Comms dew the Message for Test eee MEST 47 Read and complete the tasks in step 5 if a return fan is installed or 3 if a return fan is not installed on this screen to test the communication link between the drive s and the fan s A message s displays to indicate if communications are working properly Refer to Chapter 4 Troubleshooting for more information if communications are not working properly 48 Press Next The Cooling and Heating Setup screen displays O ccc C n EN lt o a Supply Ar Low Umit an Supply Air High Limit 15 FACTORY ONLY ae Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Configuration and Start Up 3 19 Note When in cooling mode the supply fan speed will typically be set based on the difference in temperature Delta T between the mixed air and supply air as illustrated using default values in Figure 3 1 and Figure 3 2 below unless the supply air temperature exceeds the low limit override is less than the default value of 45 F If the supply air temperature exceeds the low limit override value the fan speed will increase to the VFD output maximum value for cooling setup Figure
76. 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 FanMaster provides an alarm contact for monitoring of faults by an existing into Building Automation building automation system BAS This contact is normally closed when Systems 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 INO01B EN P December 2009 PN 65329 General Precautions Chapter 2 FanMaster Installation 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 i ATTENTION Only qualified personnel familiar with Heating proper insta
77. for a custom city can be entered during configuration on the User City Weather Data Setup screen described on page C 14 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 The data set for each location on the CD contains a diagram and chart of the Average Heating and Cooling Loads The tabulated monthly data in the chart is the data to be entered into the custom user data screen In addition a list of all cities in the NOAA weather database on the CD can be 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 A 4 Specifications and City Climate Profiles City State Albuquerque NM North America United States City State Des Moines IA City State Little Rock AFB AR City State Pierre SD Anchorage AL Detroit City MI Los Angeles Intl CA Pittsburgh Intl PA Arcata Eureka CA Dodge City Awos KS Louisville Standiford Fld KY Raleigh Durham NC Astoria Clatsop OR Duluth MN Macon Lewis Wilson GA Rapid City SD Billings Logan MT Ely Elland Field NV Madison Dane Co Rgnl W
78. g the up or down and Enter arrow buttons See City Climate Profiles on page A 3 for a complete list of available cities Supply Fan HP Supply fan motor rated horsepower Supply Fan FLA Supply fan motor rated full load amps Unit CFM AHU air flow volume Does AHU Have A Return fan installed selection Return Fan Return Fan HP Return fan motor rated horsepower Return Fan FLA Return fan motor rated full load amps Elect Cost per kWh Electricity cost in dollars per kilowatt hour Nat Gas Cost MMBTU Natural gas cost in dollars per one million BTUs Heating Efficiency Percentage of heating efficiency Damper Minimum Pos Outside air damper minimum open percentage Coolant Type AHU coolant type Choose the coolant type using the up down and Enter arrow buttons User City Press to view the User City Weather Data Setup Screen Next Press to view the Setup Date and Time Screen Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Screens and Field Descriptions C 5 Setup Date and Time Screen The Setup Date and Time screen is used to enter the current date and time SETUP DATE AND TIME 2009 0272472D09 15 15 Table C D Set Date and Time Screen Fields Field Name Set Month Description NEXT Current month numeric Set Day Current Day of
79. g 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 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 af
80. ge 4 4 Pressure Out Of Range 4 3 Return Fan Comm Fault 4 3 Return Fan Drive Fault 4 3 Setup Values At Defaults Perform Setup Per User Manual 4 4 Supply Air Temperature High 4 3 Supply Air Temperature Low 4 3 Supply Air Temperature Out Of Range 4 2 Supply Fan Comm Fault 4 3 Supply Fan Drive Fault 4 3 FanMaster Configuration 3 1 FanMaster Enclosure Ambient Temperature Limits A 1 Lifting Instructions 2 10 Mounting 2 10 Weights 2 10 FanMaster Field Descriptions C 1 FanMaster Firmware Upgrades D 1 D 3 FanMaster Overview Externally Mounted Components 1 2 FanMaster Application Considerations 1 6 FanMaster Description 1 1 FanMaster Operation 1 4 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Screens C 1 Air Handler Unit Diagram screen C 3 Cooling and Heating Setup C 10 Dashboard screen C 2 Data Collection C 13 Data Log 1 C 15 Data Log 2 C 16 Data Log 3 C 17 Fan Communication Setup C 10 Proof of Flow Setup C 12 Return Fan Setup C 9 Setup 1 C 4 Setup 2 C 6 Setup 3 C 7 Setup Date and Time C 5 Supply Fan Setup C 8 System Status C 18 User City Weather Data Setup C 14 FanMaster Startup 3 1 FanMaster Status Air Handler Unit Diagram screen 4 1 Alarm Indications 4 1 FanMaster Faulted indicator light 4 1 FanMaster Faulted signal 4 1 Field Descriptions C 1 Firmware Upgrades MicroLogix Controller D 1 PanelView D 3 Four Po
81. h 105 _ Wa _ 06 1s FanMaster Override OFF ON t 5 S i DC Com 4 From Sheet 1A 5 Building Auto D 2H i Start Stop 7 8 9 102 IA Com IV1 IV2 Outputs VAG VDC TB2 0 0 13 Com 113 VAC Proof of VDC Fan Running 14 N O 114 On VAC VDC LT1 on 116 R FanMaster Fault f Fay Com 117 VAC High CO9 T VDC Alarm iis N O 118 03 Com 119 VAC Damper 119 VDC 24 V Solenoid T N O 120 Ol Com 121 VAC FanMaster 121 VDC Not Faulted N C 122 For Customer Use 122 100 24V DC 102 0V DC To Sheet 2A To Sheet 2A Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 B 4 FanMaster Diagrams Figure B 3 FanMaster w Drive Schematic Diagram Sheet 2A From Sheet 1B From Sheet 1B From Sheet 1B Analog Input Expansion Module 1762 IF4 Slot 1 0V DC Supply Air Temp CO Sensor Damper Position Command from BAS or Pressure Sensor Signal Input Optional Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Diagrams B 5 Figure B 4 FanMaster w Drive Schematic Diagram Sheet 2B From Sheet 1A From Sheet 1A Customer Connection to 7
82. icroLogix 1100 application firmware e USB Thumb drive pre programmed with the FanMaster Panel View application firmware Important All configuration data will be set to the default values after the firmware upgrade has been completed 1 Turn off the Air Handler Unit AHU so FanMaster does not receive any run signals while the supply air fan and return air fan if installed is off If a bypass is installed on the drive you can set the drive to bypass if you want to allow the fan s to run during the firmware upgrade procedure 2 Record all FanMaster configuration data If you have not previously recorded your configuration data or it has changed since you installed FanMaster use the chart in Gather and Record Data on page 3 2 to do so 3 Stop data logging and clear the log See Start or Stop Data Collection on page 3 27 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 D 2 FanMaster Application Firmware Upgrades 4 Open the FanMaster enclosure and remove the existing memory module from the MicroLogix 1100 controller s processor gogo Pull memory module SAS Straight out of chassis U gt IN IN YY 5 Install the new mem
83. ify that the fan is operational e Verify that the damper actuator is operational e Check the transmitter probe and wiring for damage and replace if necessary e Verify the temperature using a calibrated thermometer If the temperature is different that the value in the FanMaster replace the supply air transmitter Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 4 4 Troubleshooting Alarm Outside Air Damper Signal Out Of Range Description One of the following has occurred Possible Action s e The polarity of the device wiring is incorrect Verify that the wiring is correct e The outside air damper signal is above or below the operating range OOR of the device Check the damper position switch wiring for damage and replace if necessary Check for loose wiring at the device or at terminal block 2 in the FanMaster unit Check for loose or damaged wiring to the damper actuator Check the signal from the BAS to the damper actuator If an OOR still exists replace the damper position switch Mixed Air Temperature Low One of the following has occurred e The mixed air temperature low limit may be incorrectly configured Verify that the value in the Supply Air Low Limit field on the Cooling and Heating Setup Screen on page C 10 is set appropriately e The mixed air temperature is below the low
84. installations where the AHU must maintain a constant flow of outside air 33 If a CO sensor is installed continue with the next step If a CO sensor is not installed press CO so that No CO2 displays Note If you have selected Demand Vent in the previous step and No CO2 in this step Demand Vent will be automatically changed to Variable Vent i e demand ventilation cannot be selected when a CO sensor is not installed Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 3 12 FanMaster Configuration and Start Up 34 35 36 37 38 39 40 Press Next The third Setup screen displays Mech Heat Damper Override Allow Outside Air Damper Override for Additional Savings Override Duty Cycle MAIN CO2 Demand Setpoint ppm Bara CO2 Aam Setpoint ppm 500 Pressure Low Limit in wc EET If the AHU does not have a heating system press No next to Does AHU Have Mech Heating Mech Heat changes to display No Mech Heat If the AHU does not have a cooling system press No next to Does AHU Have Mech Cooling Mech Cool changes to display No Mech Cool If FanMaster will not be allowed to override the BAS control of the outside air damper press No next to Allow Outside Air Damper Override for Additional Savings
85. ir 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 CO 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 wil
86. is pressed in two locations at the same time the presses are averaged as a single press in between the two locations Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 3 2 FanMaster Configuration and Start Up Gather and Record Data Gather the following data in order to successfully configure and start up the FanMaster Record the actual data for your installation in the table below and save the table for your records Table 3 A Installation Data Step Data Required Default Value Actual 8 City climate profile refer to City Climate Profiles on page A 3 for a complete list of available Chicago cities Note If an acceptable climate profile is not included in the list in Appendix A you can use the User City Weather Data Setup screen described on page C 14 to create and save a climate profile for your location 9 Supply fan motor nameplate horsepower HP rating 10 10 Supply fan motor nameplate full load amps FLA rating 12 2 11 ate If set to 0 in configuration value will be auto calculated based on 2 000 CFM per 30 000 13 Return fan motor nameplate horsepower HP rating if installed 5 14 Return fan motor nameplate full load amps FLA rating if installed 6 1 15 Electrical cost in dollars per kWh 0 0891 16 Natural gas cost in dollars per MMBTU 8 50 17 Heating effici
87. ith enclosed equipment These enclosures offer no protection against airborne contaminants e 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 lt 25 4 mm 25 4 mm 1 0 in 1 0 in e Allen Bradley PanelView C600 1 2 e amp Allen Bradley c FanMaster j NEMA UL Type 1 Enclosure Shown 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 A m ss tk II III M WN U MM s l 580 l pene Pea ot r 22 84 T Je QO e is IU U 4 MUI 9 75 III A Tran pa oa ma 00 0 I is anMaster R 508 00 f f 20 00 E Side View eto r i l T 253 24 Ce 9 97 Co 2 le L I Bottom View Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Installation 2 9 Figure 2 4 NEMA UL Type 4 FanMaster Enclosure Dimensions Dimensions are in
88. ive is installed the Proof of Flow Setup screen displays continue with step 54 below Proof of Flow Torg Limit Percent 54 The Proof of Flow Setup screen is used to Verify that the supply air fan and return air fan if installed is rotating in the correct direction During the test the fan s will run If the fan s is not turning in the proper direction you must reverse any two motor leads Set up the Proof of Running output The existing proof of flow sensor flow switch or pressure sensor may not provide accurate proof of flow at a reduced fan speed FanMaster will detect flow by monitoring the torque current required by the supply fan at the minimum speed If the supply fan drive is not delivering 50 of this current threshold the proof of flow output turns off The test allows the system to capture the 50 threshold value by monitoring the current supplied to the motor at the minimum fan speed Read and complete the tasks in steps 1 4 on this screen Once the test has been initiated a message box displays to indicate that the test is in progress You can touch Press to Abort Test Stop Fan at any time to stop the test and shut down the fan s If the drive s starts and stops does not run continuously verify all communication wiring between the drive s and FanMaster and that the communication cables are not installed near the power cables Allen Bradley FanMaster Energy Saving
89. iz 8h1 grt oO 41 240 Srk gt Stl oO 1 249 91 gt orl O z 189 Wi let O o Z 0 Zvl le W 149 Sek sel oO IZ 0r Ort oO x z x e Q 2 e O aw eN 1 101S 191g 817 FI O 6z O we IOVWA 0 1018 1914 00L oor wx ul ZOL 28 2NI L 101S 1214 Leh za e gzl O a d 00 OOF ni Z01 ZOL ou INI L 101S 1214 SZL SZL e 9z O z 12 149 001 oot WO9 0 1018 191d zol ZOL ue 0NI L 1005 101 Ezt wm O 9 11 0N9 Ei 1s5 00l O04 Sd z01 ZOL a IMVWA 0 101S 1914 121 ra e S 0 0 1015 1914 ZL KA O ET S0W3A 0 101S 191d 6l L 6ll O 0 0 101S 1914 Mt OZ O yo e OS0A 3VA 0 101S 1914 re an O 0 0 1015 191 7 811 git oO s os OS0W3A 0 101S 1314 re a e 1 0 0 101 191d t m Oo 23 11 149 00 EFI 42 478 601 601 okz z3 0l FEP Z 1 0 1018 1934 so1 sO uo ore ra ss Ea _ sa oO wus ao 5 ee a gt x s el lt 2 ees SOOOO9 m E ans oO aes T AAs BEEE OJ r Z N aq z01 2al 201 0 3 xO 8 I E 2 0 0 101S 914 911 0 105 0 901 4 O m ard n ica 001 Zal 001 B 15 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 B 16 FanMaster Diagrams Figure B 15 FanMaster NEMA UL Type 1 Enclosure Layout PLC CB2 PS1 SLOT 0 SLOT 1
90. l allow full fan speed and normal ventilation when and where it is most needed This is the most typical installation Alternatively the CO sensor can be mounted directly in the conditioned 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 room monitors for critical 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 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B 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 press
91. le C N Data Log Field Name January February March 1 Screen Fields Description Month selection Choose the month for which you want to view data using the up or down and Enter arrow buttons Note When the current month is selected data displayed represents the month to date values When a previous month is selected data displayed represents values for the entire month YYYY Year selection Choose the year for which you want to view data Monthly Fan kWh without Monthly kilowatt hours used to run the AHU fan s without FanMaster FanMaster Monthly Fan kWh with Monthly kilowatt hours used to run the AHU fan s using FanMaster FanMaster Monthly Outside Air Monthly BTU s used to heat the outside air without FanMaster Heating BTU w o FanMaster Monthly Outside Air Monthly BTU s used to heat the outside air using FanMaster and the Heating BTU with outside air damper override FanMaster amp Override Monthly Outside Air Monthly BTU s used to cool the outside air without FanMaster Cooling BTU w o FanMaster Monthly Outside Air Monthly BTU s used to cool the outside air using FanMaster and the Cooling BTU with FanMaster amp Override outside air damper override Monthly Average Outside Average volume of outside air in cubic feet per minute provided by the Air CFM with FanMaster AHU as calculated by FanMaster Dashboard Press to view the Dashboard Sc
92. len Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 2 16 FanMaster Installation Outside Air Damper with Electric Actuator 0 10V DC or 4 20 mA The existing outside air damper has an electric actuator with a 0 10V DC or 4 20 mA control signal i Remove the control wire from the actuator terminal and connect it to terminal 155 on TB2 in the FanMaster enclosure ii Wire terminal 153 on TB2 to the actuator terminal iii Test the system and make sure that operation does not cause an alarm in the existing system which may cause an HVAC shutdown due to opening the 4 20 mA loop or other failure to follow command alarm Outside Air Damper with Pneumatic Actuator The existing outside air damper has a pneumatic actuator with a mA to Pressure controller I to P i Either remove the control wire from the I to P and connect through the relay as in steps i a and i b above or obtain an electrically actuated pressure valve which expels the pneumatic actuator control air when the valve is actuated Use the FanMaster damper relay to switch power for the pressure valve separately sourced AC or DC power is required Outside Air Damper with Electric Actuator 0 135 Ohm The existing outside air damper has an electric actuator with a 0 135 ohm control signal i Remove the power supply wire from the actuator and co
93. lication FANM INO01B EN P December 2009 PN 65329 3 28 FanMaster Configuration and Start Up Clear the Data Logs and Important Clearing the data logs will delete all historical energy savings Collect Data data This task should only be performed when you have completed the entire FanMaster configuration task and need to begin collecting new data To clear the logs and begin collecting data 1 On the Air Handler Unit Diagram screen press Data Log The first Data Log View screen displays k JANUARY FERR MARCH YYYY Y Monthly Fan kWh with Fanbtaster Monthly Outside Air Cooling BTU with Fanktster amp Owermide LOGGING contro ET Data Collection DONE 3 Press Clear Logs A message displays to confirm that you want to delete the data stored in the log Press Yes Al historical data will be cleared from the data logs Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Status Chapter 4 Troubleshooting This chapter contains information on troubleshooting the FanMaster Important Power must be supplied and circuit breaker CB1 in the FanMaster enclosure must be set to ON in order for the Panel View terminal and MicroLogix controller to run If the Panel View screen or display on the MicroLogix controller is dark off set CB1 to OFF and check the power so
94. limit setpoint as configured in the FanMaster Verify that the fan drive is energized Verify that the fan is operational Verify that the damper actuator is operational Check the transmitter probe and wiring for damage and replace if necessary Verify the temperature using a calibrated thermometer If the temperature is different than the value displayed in the FanMaster replace the mixed air transmitter CO2 Level Above Setpoint The CO level is above the high level setpoint as configured in the FanMaster Check the sensor probe and wiring for damage Check for loose wiring at the sensor or at terminal block 2 in the FanMaster unit Check the CO level using another calibrated sensor If the reading is different than the value displayed in the FanMaster replace the CO sensor Setup Values At Defaults Perform Setup Per User Manual The FanMaster configuration data has been cleared or lost and have been reset to the default values Complete the configuration and start up procedures Refer to Configure the FanMaster on page 3 4 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Drives and FanMaster Specifications Appendix A Specifications and City Climate Profiles PowerFlex Drives Category Specification PowerFlex 400 AC Drive Ratings 200 240V AC 400 480V
95. llation 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 A ATTENTION The following information is merely a guide for 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 i ATTENTION FanMaster is a HVAC fan motor control device 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 i ATTENTION National Codes and Standards NEC VDE Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 2 2 FanMaster Installation Installation Considerations Installation Requirements Consider and plan for the following when installing
96. lose any drive or BAS control panel covers Complete the procedures in Chapter 3 FanMaster Configuration and Start Up Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Using the PanelView C600 HMI Terminal Chapter 3 FanMaster Configuration and Start Up This chapter contains the steps necessary to configure and start up FanMaster Typical values are provided as defaults where applicable The default values may not be valid for your installation and if left unchanged may affect the calculated energy savings results Verify all values in Table 3 A on page 3 2 prior to completing the configuration procedures The Panel View C600 HMI terminal is a touch sensitive operator interface that is used to monitor and program the controller in the FanMaster via a pre programmed HMI application You can navigate the screens and edit values by touching a location on the display For a description of each FanMaster screen refer to Appendix C FanMaster Screens and Field Descriptions Ze Allen Bradley PanelView C600 N a Touch Display For NEMA UL Type 4 enclosures loosen the two screws on the Panel View terminal cover in order to lift the cover and access the PanelView HMI terminal Important Analog touch screens are intended for single presses at a time If the touch screen
97. lta T Min field when heating the conditioned space Press the value next to VFD Output Max and enter the percentage of full speed that the drive will run the supply fan when the temperature difference is at or above the maximum value set in the corresponding Delta T Max field when heating the conditioned space 51 The Supply Air Low Limit field below SA Low Limit Override is used to set a supply air low temperature limit below which FanMaster will run the supply air fan at full speed 100 to avoid freezing up the cooling system Press the value next to Supply Air Low Limit and enter the supply air low temperature limit at which FanMaster will command the supply fan speed to run at full speed Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Configuration and Start Up 3 23 52 The Supply Air High Limit field below SA High Limit Override is used to set a supply air high temperature limit above which FanMaster will run the supply air fan at full speed 100 to avoid overheating the heating system Press the value next to Supply Air High Limit and enter the supply air high temperature limit at which FanMaster will command the supply fan to run at full speed 53 Press Next If you have installed an evaluation unit the Data Collection screen displays continue with step 56 below If a dr
98. ltiplies 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 Average Ventilation and Infiltration Loads Outside Air vs 75 F 60 RH summer 68 F 30 RH winter res 10000 Load Btu cf E Average Sensible Cooling Load E Average Sensible Heating Load O Average Latent Coolmg Drymg Load O Average Latent Heating Humidifying Load Average Sensible Average Sensible Average Latent Average Latent Cooling Load Heating Load Cooling Load Heating Load Btm cfm Btu cfm Btu c m Btu cfm 148572 32998 21427 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
99. lts Step 4 Set Return Fan Used to set the return fan parameter values Params AHU Press to view the Air Handler Unit Diagram Screen Back Press to view the Supply Fan Setup Screen Next Press to view the Fan Communication Setup Screen Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 C 10 Fan Communication Setup Screen FanMaster Screens and Field Descriptions The Fan Communication Setup screen is used to test the communication link between the supply and return if installed drive and fan FAN COMMUNICATION SETUP Step 5 Power Up Retum Fan WFO and Power Up Supply Fan Press Test WFO Comms dew the Message for Test Results Set HOACS3to Auto if installed Table C I Field Name Step 5 or Step 3 Test VFD Comms Fan Communication Setup Screen Fields Description Used to test the communication link between the drives and fans Note If a return fan is not installed Step 3 displays in place of Step 5 AHU Press to view the Air Handler Unit Diagram Screen Back Press to view the Supply Fan Setup Screen or Return Fan Setup Screen Next Cooling and Heating Setup Screen Press to view the Cooling and Heating Setup Screen The Cooling and Heating Setup screen is used to set up cooling and heating limits and fan responses to those limits Desr
100. m 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 INO01B 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 sup
101. m value when heating the conditioned space 50d The percentage of full speed that the drive will run the supply fan when the temperature 100 difference is at or above the maximum value when heating the conditioned space 51 The supply air low temperature limit at which FanMaster will command the supply fan speed 45 to run at full speed to avoid freezing up the cooling system 52 The supply air high temperature limit at which FanMaster will command the supply fan to run 145 at full speed to avoid overheating the heating system Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 3 4 FanMaster Configuration and Start Up Important Verify that all steps in Chapter 2 FanMaster Installation are complete and that the 20 COMM H communication adapter is installed connected and that the rotary switches are set correctly before completing the FanMaster configuration procedure below Configure the FanMaster 1 Apply power to FanMaster and apply power to the drive s if installed The PanelView HMI will boot up this may take 2 3 minutes 2 Because the systems has not yet been configured various alarms will display Press Ack in the alarm banner to acknowledge each alarm When the Important Notice screen displays the unit is ready for configuration Evaluation Unit Install Only Permanent Install Only Allen Bradley FanMaster
102. n Juan Puerto Rico Asia City Country Tokyo Japan Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Selection PF400 Keypad Only Available Drive Types Description PowerFlex 400 drive with an integral keypad with Hand Off Auto HOA mode no HOA switch no speed potentiometer pot and no bypass Specifications and City Climate Profiles A 5 Operation When the keypad is in Auto FanMaster controls the drive start stop and speed commands When the keypad is in Hand the keypad controls the drive start stop and speed PF400 HOA amp Speed Pot No Bypass PowerFlex 400 drive with an integral keypad HOA switch speed pot and no bypass When HOA is in Auto FanMaster controls the fan start stop and speed When HOA is Off the fan is always off When HOA is in Hand the Fan starts and the speed is controlled by the speed pot PF400 Full Feature Bypass w Keypad Control NEMA UL Type 1 only PowerFlex 400 drive with a full feature bypass and integral keypad that allows Hand Off Auto HOA mode When HOA is in Auto and the Bypass Switch in Drive FanMaster controls the fan start stop and speed When HOA is in Off and the Bypass Switch in Drive the fan is always off When HOA is in Hand and the Bypass Switch in Drive the keypad controls the fan start stop and s
103. nMaster For detailed drive spacing lifting mounting grounding and other detailed installation instructions refer to the following publications PowerF lex 400 AC Drive e PowerFlex 400 AC Drive Packages for Fan amp Pump Applications Installation Manual publication 22C IN002 PowerFlex 70EC AC Drive e PowerFlex 70 Adjustable Frequency AC Drive Installation Instructions publication 20A INO09 PowerFlex 700VC AC Drive e PowerFlex 700 Adjustable Frequency AC Drive Frames 0 6 Installation Instructions publication 20B INO19 PowerF lex 753 AC Drive e PowerFlex 750 Series AC Drive Installation Instructions publication 750 INO01 For detailed information on how to properly wire and ground drives and determine maximum motor cable lengths refer to e Wiring and Grounding Guidelines for PWM AC Drives publication DRIVES INOO1 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Installation 2 7 Install the FanMaster Enclosure Environment e 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 w
104. nd time Dashboard Press to view the Dashboard Screen AHU Press to view the Air Handler Unit Diagram Screen System Status Screen you are currently viewing Data Log Press to view the Data Log 1 Screen Set Date Press to view the Setup Date and Time Screen Setup press to view the Setup Screen 1 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Required Equipment Upgrade the FanMaster MicroLogix 1100 Controller Application Firmware Appendix D FanMaster Application Firmware Upgrades Complete all steps in this appendix to upgrade your FanMaster MicroLogix 1100 and Panel View terminal application firmware Note You may be required to upgrade the Panel View operating system firmware to the latest available prior to upgrading the FanMaster Panel View application firmware The Panel View operating system must be version 1 11 or higher in order to run the FanMaster PanelView application version 2 00 The Panel View operating system firmware is present on the PanelView operating system boot up screen visible at the initial application of power to the unit For information about downloading and installing the PanelView operating system firmware upgrade visit http ab com eoi graphicterminals downloads html e 1763 MM1 Memory Module for the MicroLogix 1100 pre programmed with the FanMaster M
105. nd view all historical data for the selected time period Refer to Appendix C FanMaster Screens and Field Descriptions for a description of the fields contained on the Data Log screens Note the month and date can be changed on each Data Log screen Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Configuration and Start Up 3 27 Start or Stop Data Collection To start or stop collecting data 1 On the Air Handler Unit Diagram screen press Data Log The first Data Log View screen displays P MARCH Ee YYYY yY Monthly Fan kh without Fanttaster Monthly Fan kh with Fanbtaster Monthly Outside Ar Heating BTU wio Fantetaster Monthly Outside Ar Heating BTU with Fanttaster amp Owerride Monthly Outside Ar Cooling BTU wo Fanttaster Monthly Outside Air Cooling BTU with Farnhaazter amp Override Monthly Average Outside Air CFhd with Fantvtaster DASH I JATA LOGGING BOARD STATUS JG contro NEAT 2 Press Logging Control The Data Collection screen displays Data Collection DONE e To start collecting data press Start Collecting Stopped will change to display Collecting e To stop collecting data press Stop Collecting Collecting will change to display Stopped Allen Bradley FanMaster Energy Saving Package Installation Manual Pub
106. ndix A Appendix B Appendix C Table of Contents Important User Information 0 eect nen eens 1 2 General Information Who Should Use This Manual 0 0 0 cece ene eens p l What is Contained in this Manual 2 0 0 cee eens p l Manual Conventions 2 p cgs dagedy ase ohae bes woae pawaq deed aa paws p l Reference Materials u ul chased hee uqata mat Gana y Hee RAG eS usha ee p 2 FanMaster Overview RanMaster Description 6 400504 eee aid Meade ane uag eka ease ee ON eae ee 1 1 FanMaster Externally Mounted Components 1 2 FanMaster Op rati n u u dada eee dene ee ee Se aed ea dea eds 1 4 FanMaster Application Considerations 0 0 c eee eee eee eee eee 1 6 Integration of FanMaster into Building Automation Systems 1 12 FanMaster Installation General Precautions soceri aoa eaa a cece eee eee eee eee eaae 2 1 Installation Considerations usss usay usa ccc cece eee eee eee ae 2 2 Installation Requirements 0 0 0 0 cee tenet eens 2 2 Instalati Oise us uyu su Ya EOE AE aan Usu a ae 2 4 FanMaster Configuration and Start Up Using the Panel View C600 HMI Terminal 3 1 Gather and Record Data 0 0 nt eee e ene anes 3 2 Configure the PanMastet i 66 00 o sGese bas Gea dad Gee ee dae ee pals 3 4 View Detailed Data Log Information 3 26 Start or Stop D
107. ng 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 INO01B 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 below The tabulated monthly data in the chart is the 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 mu
108. nnect it to terminal 155 on TB2 in the FanMaster enclosure ii Wire terminal 153 on TB2 to the actuator power supply terminal Important The installer must determine and ensure the proper operation of this contact when used to force the damper closed Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Installation 2 17 16 Optional required when using the constant ventilation option rather than the default demand ventilation option If FanMaster will be used to control the outside air damper for constant ventilation control connect the damper position control wires to the appropriate terminals on the drive Important The analog output terminal used on the drive must be set for a 4 20 mA signal only Verify that the appropriate drive DIP switch or jumper is properly set for a 4 20 mA signal or component damage may occur Refer to the appropriate drive User Manual for details If the control signal is 0 10V DC or 0 135 Ohms a converter adapter must be purchased separately and be installed for both the input and output signals For PowerFlex 400 drives connect the damper position control wires to terminals 14 and 15 in the drive For PowerFlex 70EC drives connect the damper position control wires to terminals 22 and 23 in the drive For PowerFlex 700VC drives connect the damper position control
109. nts e 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 or Figure 2 4 on page 2 9 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 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B 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 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 i ATTENTION Do not route signal and control wiring with 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 ForNE
110. nual Publication FANM IN001B EN P December 2009 PN 65329 A Air Handler Unit Diagram screen C 3 Application Firmware Upgrades D 1 D 3 B Bypass Switch Operation A 5 C Carbon Dioxide Sensor Installation Considerations 1 2 City Climate Data Applying 1 9 City Climate Profile Create C 14 Clear Logs and Collect Data 3 28 Climate Profiles A 3 CO2 Demand Setpoint ppm Determining 1 11 CO2 Level Above Setpoint alarm 4 4 CO2 Level Out Of Range alarm 4 2 Configure FanMaster 3 1 Considerations for Installation 2 2 Constant Ventilation Mode 1 6 Control Wiring 2 12 Cooling and Heating Setup screen C 10 Create and Save a City Climate Profile C 14 D Damper Position Indicator Switch Installation Considerations 1 3 Dashboard screen C 2 Data Collection screen C 13 Data Log 1 screen C 15 Data Log 2 screen C 16 Data Log 3 screen C 17 Data Logs Viewing 3 26 Demand Ventilation Mode 1 5 Dimensions NEMA UL Type 1 Enclosure 2 8 NEMA UL Type 4 Enclosure 2 9 Index Drive Types A 5 E Estimated Savings Calculator Operation 1 6 F Fan Communication Setup screen C 10 Fan Speed Reduction 1 4 Fan Starter Current Sensor Installation Considerations 1 4 Fan Starter Hard Wired Interconnection Installation Considerations 1 4 FanMaster Alarms CO2 Level Above Setpoint 4 4 CO2 Level Out Of Range 4 2 Mixed Air Temperature Low 4 4 Mixed Air Temperature Out Of Range 4 2 Outside Air Damper Signal Out Of Ran
111. nual 20A UM001 PowerFlex 700 Adjustable Frequency AC Drive Frames 0 6 Installation 20B IN019 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 INO01 PanelView Component HMI Terminals User Manual 2711C UM001 MicroLogix 1100 Programmable Controllers User Manual 1763 UM001 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 Description Chapter 1 FanMaster Overview 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
112. ocket and or torque e 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 Nem 9 0 Ibein GND Ground 6 AWG 16 AWG 2 3 Nem 20 4 lbein I O and Signal 12 AWG 22 AWG 0 6 0 8 Nem 4 5 7 1 Ibein Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 2 3 FanMaster Installation Typical FanMaster and Drive Installation Figure 2 1 oA OV 94 10 DAOOL 9302 00 X 4 MOd 191SeWuej QONOS JAMO Indu o JoUoD dols uels Syg p sn J YMS YOIMS JUUNI JOJO Ue uollisod JedWeq 2 WY Ay f y Jy A ddns Yj Yj Z apisino Wa ue Ajddns sued dwa sued dwa eoeds pauoipuod sy Ajddns 1IV p XIIN l uny sneyx 4 sneyxa JOSUAS APIXOIg UOGeD ue unyay jeuondo 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 inst
113. ommunication Setup Screen Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Return Fan Setup Screen FanMaster Screens and Field Descriptions C 9 The Return Fan Setup screen is used to set the return fan parameters in the drive to the correct values PowerFlex 400 70EC and 700VC Drives RETURN FAN SETUP Step 3 Power Up Retum Fan VFO Set HOAto OFF it installed Power Down Supply Fan FD If using PFFOEC or PFFOOWC set Comm Parameters per Fanhtaster Installation bianual For all drives press Set Retum Fan Detautts then Power Down Return Fan VF D installed Power Down Supply Fan VF D Press Set Return Fan Parameters Step 4 Power Up Return Fan VFO Set HOAto OFF if NEXT PowerFlex 753 Drives Only RETURN FAN SETUP Step 3 Power Up Return Fan VFO Power Down Supply Fan VFO Set Return Fan parameters to defaults per Fanhtaster installation manual Power Retum Fan FD fully off then back on Set additional Parameters per Fantvaster installation manual Power Retum Fan FD fully off then back on Fan Parameters Step 3 Power Up Retum Fan VFO Set HOAto OFF f installed Power Down Supply Fan VFO Press Set Return MEST Table C H Return Fan Setup Screen Fields Field Name Description Step 3 Set Return Fan Used to set the return fan to the default values Defau
114. ons 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 in the return air and will override the reduced fan speed at any time the CO level rises 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 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 level does not require additional ventilation By closing 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 level exceeds the user specified setpoint 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
115. ormation contained on each FanMaster screen The screens are listed in order of appearance as you complete the configuration procedures Screen Page 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 C7 Supply Fan Setup Screen C 8 Return Fan Setup Screen C 9 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 C 14 Screen Data Log 1 Screen C 15 Data Log 2 Screen C 16 Data Log 3 Screen C 17 System Status Screen C 18 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 C 2 FanMaster Screens and Field Descriptions Dashboard Screen The Dashboard screen provides a quick view of the energy savings performance of FanMaster The green yellow and red color bands on the gauges identify the most desirable to least desirable readings respectively v2 00 o a FanMaster Allen Bradley ee Table C A Dashboard Screen Fields Field Name Avg Fan Speed Description Average percentage of full speed of the fan s speed since start up or the last time the logs were cleared A lower value on this gauge indicates lower fan speeds Avg Energy Sa
116. ory module Verify that the module is fully seated in place The new application firmware will be installed on the next power cycle Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Application Firmware Upgrades D 3 Upgrade the FanMaster 1 Insert the USB thumb drive containing the FanMaster application PanelView Application firmware into the USB port on the back of the Panel View terminal Firmware USB host port N lt E IOO trans SSS Back View 2 Press Setup on the Air Handler Unit Diagram screen You are prompted to enter a user name and password Password AOARO 3 Press in the User field and using the keypad type s 4 Press in the Password field and using the keypad type 258 and press Enter Zl The first Setup screen displays Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 D 4 FanMaster Application Firmware Upgrades 5 Press Next until the Cooling and Heating Setup screen displays Delta T MIN 5 Detta T MIN a Delta T MAX Delta T MAK 5 VFO Output MAK 100 VFO Dutput MAX 1 Lil VFO Dutput MIIN 50 VFO Output MIIN 5
117. pad is in Auto FanMaster controls the drive start stop and speed When the switch is in Drive and the keypad is in Hand the keypad controls the drive start stop and speed When the switch is in Bypass the fan is line started and runs full speed via the Bypass Contactor PF70EC Keypad or basic PowerFlex 70EC drive with an integral keypad and When the keypad is in Auto FanMaster controls the drive Bypass a basic bypass 9 start stop and speed commands When the keypad is in Hand the keypad controls the drive start stop and speed PF700VC Keypad or basic PowerFlex 700VC drive with an integral keypad and When the keypad is in Auto FanMaster controls the drive Bypass a basic bypass start stop and speed commands When the keypad is in Hand the keypad controls the drive start stop and speed PF753 Keypad or basic PowerFlex 753 drive with an integral keypad and a When the keypad is in Auto FanMaster controls the drive Bypass basic bypass 2 9 start stop and speed commands When the keypad is in Hand A full feature bypass allows the motor to be manually transferred from drive output to the AC line or from the AC the keypad controls the drive start stop and speed ine to the drive while the motor is at zero 0 speed and a bypass control interface which provides status indication and allows for remote activation of the bypass circuit FanMaster cont
118. peed When HOA is in Auto and the Bypass Switch in Bypass FanMaster controls the fan start stop via the Bypass Contactor line start When HOA is in Off and the Bypass Switch in Bypass the fan is always off When HOA is in Hand and the Bypass Switch in Bypass the fan line starts immediately and continues to run via the Bypass Contactor PF400 Full Feature Bypass w HOA amp Speed Pot NEMA UL Type 4 only PowerFlex 400 drive with a full feature bypass integral keypad that allows Hand Off Auto HOA mode and speed pot When HOA is in Auto and the Bypass Switch in Drive FanMaster controls the fan start stop and speed When HOA is in Off and the Bypass Switch in Drive the fan is always off When HOA is in Hand and the Bypass Switch in Drive the fan starts and the speed is controlled by the speed pot When HOA is in Auto and the Bypass Switch in Bypass FanMaster controls the fan start stop via the Bypass Contactor line start When HOA is in Off and the Bypass Switch in Bypass the fan is always off When HOA is in Hand and the Bypass Switch in Bypass the fan line starts immediately and continues to run via the Bypass Contactor PF400 Basic Bypass w 4 Pos Switch PowerFlex 400 drive with a basic bypass and a four position switch determines the state of operation When the switch is in Drive and the key
119. ply 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
120. pply air fan drive fault has occurred e View the drive HIM display to identify the fault code and refer to the Troubleshooting section of the PowerFlex 400 AC Drive for Fan amp Pump Applications User Manual publication 22C UM001 for more information Supply Air Temperature High One of the following has occurred e The supply air temperature high limit value may be incorrectly configured Verify that the value in the Supply Air High Limit field on the Cooling and Heating Setup Screen on page C 10 is set appropriately e The supply air temperature is above the high limit setpoint as configured in the FanMaster Verify that the fan drive is energized e Verify that the fan is operational e Verify that the damper actuator is operational e Check the transmitter probe and wiring for damage and replace if necessary e Verify the temperature using a calibrated thermometer If the temperature is different that the value in the FanMaster replace the supply air transmitter Supply Air Temperature Low One of the following has occurred e The supply air temperature low limit may be incorrectly configured Verify that the value in the Supply Air Low Limit field on the Cooling and Heating Setup Screen on page C 10 is set appropriately e The supply air temperature is below the low limit setpoint as configured in the FanMaster Verify that the fan drive is energized e Ver
121. r 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 seldo
122. ram Figure B 4 on page B 5 for details 15 If using constant ventilation mode continue with step 16 on page 2 17 The FanMaster damper control override commands the damper to close periodically in order to reduce the amount of outside air provided to the AHU to further reduce costs associated with cooling and heating The damper override contact at terminals 119 and 120 on TB2 in the FanMaster enclosure can be used to operate contact relay CR3 in the FanMaster enclosure or a customer supplied interposing relay or solenoid to close the damper when the output is turned on Using the damper override contact output to energize CR3 and wiring the existing damper control or power signals through the normally closed contact on CR3 will close the damper when the output is on Make the following connections for all installations Refer to the schematic diagrams in Figure B 2 on page B 3 and Figure B 4 on page B 5 for details a Install a jumper wire between terminals 1 and 152 on TB2 in the FanMaster enclosure b Install a jumper wire between terminals 151 and 119 on TB2 c Install a jumper wire between terminals 120 and N on TB2 d Complete one of the following sets of steps below based on your installation Outside Air Damper with Electric Actuator 0 10V DC or 4 20 mA on page 2 16 Outside Air Damper with Pneumatic Actuator on page 2 16 Outside Air Damper with Electric Actuator 0 135 Ohm on page 2 16 Al
123. reen AHU Press to view the Air Handler Unit Diagram Screen System Status Press to view the System Status Screen Data Log Screen you are currently viewing Logging Control Press to view the Data Collection Screen Next Press to view the Data Log 2 Screen Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 C 16 FanMaster Screens and Field Descriptions Data Log 2 Screen The second Data Log screen is used to display additional detailed monthly energy and savings data calculated by FanMaster k JANUARY FERRU MARCH amp lt Yyyy Monthly Fan cost without Fanttaster Monthly Fan cost with Fanttaster Monthly Outside Air Heating cost wio Fantetaster Monthly Outside Ar Cooling cost wo Fanhtaster Monthly Total HAC Operational Hours Monthly Outside Air Heating cost with Fanhtaster 2 Owerride Monthly Outside Ar Cooling cost with Fanktaster amp Overide BACE Table C O Data Log 2 Screen Fields Field Name January February March Description Month selection Choose the month for which you want to view data Choose the month for which you want to view data using the up or down and Enter arrow buttons Note When the current month is selected data displayed represents the month to date values When a previous month is selected data displayed represents values for the entire month
124. reen The System Status screen is used to display additional detailed monthly energy and savings data collected by the FanMaster BAS Start Stop Signal Position MIN Table C Q System Status Screen Fields Field Name Spd Command Description Current percentage of supply fan motor full speed Normal Speed Indicates that the supply fan motor is at Minimum Normal or Full speed Supply Air Temp F Current supply air temperature Mixed Air Temp F Current mixed air temperature Delta T F Current difference in air temperature between the mixed and supply air CO2 Level ppm Current CO level if monitored Avg CO2 Level ppm Current average monthly CO level if monitored Bldg Pres InWc Current building air pressure if monitored BAS Damper Cmd Current outside air damper percentage open as commanded by the BAS BAS Start Stop Signal Indicates whether the BAS is currently commanding the supply air fan to Start or Stop Damper Position Indicates whether the outside air damper is currently in the Min Max or Econ position Htg Clg Mode Indicates whether the AHU is currently in Cooling Heating or Sat mode Data Collect Indicates whether data collection is currently Collecting or Stopped 02 24 2009 09 34 Current date a
125. reen displays Main Copy File From Fan lasty 200 File Manager Communication Copy Application Startup Application Copy Recipe Display Copy Alarm History ate and Time System Information 10 Press Copy Application below the From field The Copy To screen displays Verify that Internal displays in the To field before proceeding Main File Manager Communication Startup Application Display ate and Time System Information Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Application Firmware Upgrades D 7 11 Press Copy A message displays indicating that the copy was successful Press OK The File Manager screen displays Main File Manager File Manager Source A Internal Communication FariMastrv 200 Startup Application Display ate and Time System Information 12 Verify that Internal is displayed in the Source field select the new PanelView application file in the list using the blue arrow keys and press Set As Startup below the list The Startup Application screen displays Main Startup Application File Manager FanMlast 200 Communication Change Startup Startup Application Application Display ate and Time System Information Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B
126. rol in Auto Bypass mode is not available on the return air fan if installed operation Operation in Bypass mode is limited FanMaster will not provide a proof of run signal and CR1 and CR2 will not energize to provide Fan Running Aux Contacts A basic bypass allows the motor be manually transferred from the drive output to the AC line or from the AC line to the drive and no remote or automatic bypass Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 A 6 Specifications and City Climate Profiles Notes Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Drawing Index Appendix B FanMaster Diagrams Schematics FanMaster w Drive Drawing Page igure B T FanMaster w Drive Schematic Diagram Sheet 1 2 Figure B 2 FanMaster w Drive Schematic Diagram Sheet 1B B Figure B 3 FanMaster w Drive Schematic Diagram Sheet 2A B 4 Figure B 4 FanMaster w Drive Schematic Diagram Sheet 2B B 5 Schematics FanMaster Evaluation Unit Dawn Page Figure B 5 FanMaster Evaluation Unit Schematic Diagram Sheet TA B 6 Figure B 6 FanMaster Evaluation Unit Schematic Diagram Sheet 1B B 7 Figure B 7 FanMaster Evaluation Unit Schematic Diagram Sheet 2A B 8 Inter Connect Drawing Page Figure B 8 Interconnect Diagram for PowerFlex 400 Driv
127. rument 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 e 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 e 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 e Using the two screws and mounting flanges provided on
128. s 20 degrees above horizontal breaks 15 degrees below horizontal Operating Temp 30 130 F 34 54 C Enclosure UL 94V 0 flammability rating Optional Instrumentation Current Switch provided w evaluation unit only Type AC DC Switch Voltage Max 30V AC 40V DC Current Max 500 mA Voltage on 24V DC 150 mA lt 0 1V Input Current Min 1 5 A Input Current Max 200 A Recommended Modus T30 or M30 Differential Pressure Transmitter customer supplied Supply Voltage 11 32V DC Power 0 9 VA Analog Output 4 20 mA limited to approx 3 85 mA at low end of span approx 25 mA at upper end Overpressure 8 x pressure range or 8 W C 1992 8 Pa whichever is greater Operating Temp 0 45 C 32 115 F Medium Air or inert gases Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 City Climate Profiles Specifications and City Climate Profiles A 3 The tables below include the cities by geographical area that are pre loaded in the FanMaster database and are selected on the first Setup screen e North America United States on page A 4 e North America Canada on page A 4 Europe on page A 4 Central and South America on page A 4 e Asia on page A 4 If one of the pre loaded cities in the FanMaster database does not provide a comparable climate for the installation location data
129. s the blue Enter 5 key d Press the Folders key E2 e Press the blue right arrow 6 key g until the MEMORY folder displays m f Press the blue down arrow key to select Set Defaults g Press the blue Enter 5 key O Host and Ports Preferred should be selected u h Press the blue Enter 5 key Warning Sets most parameters in the Host device and all ports to factory defaults displays i Press the button below the ENTER text on the screen A faulted message displays j Press the button under the CLR text on the screen or the red Stop key k Turn off power to the drive and wait until the display is off l Re apply power to the drive If a message displays prompting you to perform a PowerFlex 753 startup press the button below the Abort text on the screen press the blue down arrow 2 key to select Yes and press the button under the ENTER text on the screen m Press the Folders key n Press the blue down arrow 2 key to highlight 06 20 COMM H o Press the blue 5 key The DEV PARAM folder should be displayed p Press the blue 5 key Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 3 16 FanMaster Configuration and Start Up r S aa ab ac Press the button below the PAR text on the screen Pre
130. sition Switch Operation A 5 H Heating Efficiency Determining 1 11 Heating Only or Cooling Only HVAC Systems Applying 1 8 HOA Operation A 5 HVAC Systems with Electric Heating Elements Applying 1 9 HVAC Systems With No Return Air Applying 1 9 l 1 0 Wiring 2 12 Input Power Requirements A 1 Installation Considerations 2 2 Drive 2 5 FanMaster Enclosure 2 7 Instruments 2 4 Required Data 3 2 Integration of FanMaster into Building Automation Systems 1 12 Interconnect Diagrams B 1 K Keypad Operation A 5 L Layout Diagrams B 1 Lifting FanMaster Enclosure 2 10 M Minimum Damper Pos Determining 1 11 Mixed Air Temperature Low alarm 4 4 Mixed Air Temperature Out Of Range alarm 4 2 Multi Stage Heating or Cooling Systems Applying 1 9 O Outside Air Damper Override Applying 1 8 Outside Air Damper Signal Out Of Range alarm 4 4 P PanelView C600 terminal 3 1 Potentiometer Operation A 5 Power Source Requirements 2 2 Power Wiring 2 11 PowerFlex 400 AC Drive Ratings A 1 PowerFlex 400 Drive Installation 2 5 Pressure Low Limit InWC Determining 1 12 Pressure Out Of Range alarm 4 3 Proof of Flow Setup screen C 12 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 Proportional Heating and Cooling Control Applying 1 7 Publications Reference p 2 R Reference Material p 2 Required Installation Data 3 2 Required Tools 2
131. ss the button below the down arrow on the screen not the blue down arrow to view parameter 32 RTU Param Mode Press the button below the ENTER text on the screen Press the button below the EDIT text on the screen Press the button below the up arrow on the screen not the blue up arrow to select 32 Bit Parameters Press the button below the ENTER text on the screen Press the button below the PAR text on the screen Press the button below the down arrow on screen twice not the blue down arrow to view parameter 30 Stop Bits Cfg Press the button below the ENTER text on the screen Press the button below the EDIT text on the screen Press the button below the down arrow on the screen not the blue down arrow to select 1 Bit 0 Press the button below the ENTER text on the screen Complete the next instruction as directed on the FanMaster screen Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 FanMaster Configuration and Start Up 3 17 44 Press Next If a return fan is not installed the Fan Communication Setup screen displays continue with step 47 For return fan setup continue with step 45 below RETURN FAN SETUP Step 3 Power Up Retum Fan VFO Set HOAto OFF it installed Power Down Supply Fan WFO If using PF7DEC or PFFOOWE set Comm Parameters per Fantes
132. t 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 FanMaster Installation 2 13 PowerFlex 70EC 700VC or 753 Drive Important When installing a PowerFlex 753 drive the 20 COMM H communication adapter requires the 20 750 20COMM carrier option module Important Leave the 20 COMM H adapter rotary node address switches set to 00 and set the network protocol switch to RTU Soeoso Important The communication cable maximum length should not exceed 500 m 1 640 ft a For PowerFlex 753 drives only install the 20 COMM H RS 485 HVAC adapter in the drive according to the installation instructions in the 20 750 20COMM Option Card Installation Instructions publication 750COM INOO1 b Connect the 20 COMM H adapter via the RS 485 cable to TB3 in the FanMaster enclosure Refer to the interconnect diagrams for the PowerFlex 70EC Figure B 9 on page B 10 PowerFlex 700VC Figure B 10 on page B 11 or PowerFlex 753 Figure B 11 on page B 12 c Continue with step 10 on page 2 14 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 6
133. t to Refer to View Detailed Data Log Information page 3 26 Start or Stop Data Collection page 3 27 Clear the Data Logs and Collect Data page 3 28 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 3 26 FanMaster Configuration and Start Up View Detailed Data Log Information You can view detailed historical energy saving data logged by the FanMaster 1 On the Air Handler Unit Diagram screen press Data Log The first Data Log View screen displays k JANUARY FEBRUARY MARCH t YYYY yY Monthly Fan kWh without Fanttaster Monthly Fan kh with Fanhtaster honthly Outside Air Heating BTU wio Fantetaster Monthly Outside Ar Heating BTU with Fanttaster amp Owerride Monthly Outside Air Cooling BTU wio Fanttaster Monthly Outside Air Cooling BTU with Fanhtaster 2 Override Monthly Average Outside Air CFhd with Fantvtaster LOGGING contro ET 2 To select a specific month for which you want to view data press the up and down arrows rw g below the list of months to scroll to and choose a month Press Enter l to apply your selection The selected month will be highlighted To select a year for which you want to view data press the field displaying the year and enter the desired value Press Enter B to apply your selection Press Next on this screen and subsequent screens to access the next Data Log screen a
134. tem selection Pressure FanMaster uses an optional pressure sensor Pressure or does not use an optional pressure sensor No Pressure selection Demand Vent Constant Vent Variable Vent Demand ventilation Demand Vent constant ventilation Constant Vent or Variable ventilation no CO Variable Vent mode selection Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Setup Screen 3 FanMaster Screens and Field Descriptions C 7 Field Name Description CO2 CO sensor CO2 or no CO sensor No CO2 installed selection AHU Press to view the Air Handler Unit Diagram Screen Back Press to view the Setup Date and Time Screen Next Press to view the Setup Screen 3 The third Setup screen is used to enter data required to configure the FanMaster for your installation Allow Outside Air Damper FEG Dees Override for Additional Savings S Override Duty Cycle 50 oe CO2 Demand Setpoint ppm no Pressure Lom Limit inuu on CO2 Aam Setpoint ppm G00 NO Mech Heat Table C F Setup Screen 3 Fields Field Name Description Does AHU Have Mech Mechanical heating Yes or no mechanical heating No system Heating installation selection Does AHU Have Mech Mechanical cooling Yes or no mechanical cooling No system installation Cooling selection Allow Outside Air FanMaster overri
135. ter Installation bianual For all diwes press Set Retum Fan Detautts then Power Down Return Fan WFO Step 4 Power Up Return Fan FD Set HOAto OFF iif installed Power Down Supply Fan WFO Press Set Return Fan Parameters NEXT PowerFlex 753 Drives Only RETURN FAN SETUP Step 3 Power Up Retum Fan VFO Power Down Supply Fan FD Set Return Fan parameters to defaults per Fanhtaster installation manual Power Retum Fan FD fully off then back on Set additional Parameters per Fantvtaster installation manual Power Retum Fan WFD fully off then back on Step 4 Power Up Retum Fan VFO Set HOAto OFF f installed Power Down Supply Fan VF D Press Set Return Fan Parameters 45 Read and complete the tasks in steps 3 and 4 on the Return Fan Setup screen to set the return fan parameters in the drive to the correct values For PowerFlex 400 drives complete the tasks on the Return Fan Setup screen only For PowerFlex 70EC 700VC or 753 drives complete the tasks on the screen and the appropriate steps detailed in Setting the Parameters in a PowerFlex 70EC or 700VC Drive on page 3 14 or Setting the Parameters in a PowerFlex 753 Drive on page 3 15 only when instructed to do so Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 3 18 FanMaster Configuration and Start Up 46 Press Next The Fan Communication S
136. ter Monthly cooling cost savings in dollars using FanMaster to run the AHU Speed Cooling Savings w o Override fan s at a reduced speed without the outside air damper override Monthly Add l Damper Override Heating Cooling Savings Monthly savings in dollars from using the outside air damper override feature when heating and cooling Monthly Total FanMaster Savings Monthly total energy heating and cooling cost savings in dollars using FanMaster to run the AHU fan s at a reduced speed with the outside air damper override feature Year to Date Total FanMaster Savings Year to date total energy heating and cooling cost savings in dollars using FanMaster to run the AHU fan s at a reduced speed with the outside air damper override feature Lifetime Total FanMaster Savings Lifetime total energy heating and cooling cost savings in dollars using FanMaster to run the AHU fan s at a reduced speed with the outside air damper override feature Dashboard Press to view the Dashboard Screen AHU Press to view the Air Handler Unit Diagram Screen System Status Press to view the System Status Screen Data Log Screen you are currently viewing Back Press to view the Data Log 2 Screen Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 C 18 FanMaster Screens and Field Descriptions System Status Sc
137. ter 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 level for the building s 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 conditi
138. the Enter key again g Press the Down arrow key once to view parameter 32 RTU Param Mode h Press the Enter key i For PowerFlex 70EC drives press the 0 key for PowerFlex 700VC drive press the 1 key j Press the Enter key k Press the down arrow key twice to view parameter 30 Stop Bits Cfg l Press the Enter key m Press the 0 key n Press the Enter key o Complete the next Instruction as directed on the FanMaster screen Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 FanMaster Configuration and Start Up 3 15 Setting the Parameters in a PowerFlex 753 Drive Important When removing power from the drive s as directed in the steps on this screen verify that the drive is fully de energized by waiting until the HIM module LED display is off a Ifa Device Conflict message displays press the button below the FIX text displayed on the screen then press the button below the ENTER text displayed on the screen to confirm b Ifa message appears prompting you to perform a PowerFlex 753 startup press the button below the Abort text on the screen press the blue down arrow 2 key to select Yes and press the button under the ENTER text on the screen c If any other messages display press the button under the CLR text on the screen or choose the desired language and pres
139. 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 val
140. uary February March Month selection Choose the month for which you want to enter weather data using the up or down and Enter arrow buttons Average Sensible The average sensible cooling load in BTU CFM for the selected month Cooling Load BTU CFM Average Sensible The average sensible heating load in BTU CFM for the selected month Heating Load BTU CFM Average Latent Cooling The average latent cooling load in BTU CFM for the selected month Load BTU CFM Average Latent Heating The average latent heating load in BTU CFM for the selected month Load BTU CFM Save Changes Saves the values currently displayed in the fields for the selected month Data must be entered and saved for each month of the year Cancel Changes Cancels all changes made before the last save The last saved data if any re displays Back Press to view the Setup Screen 1 Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM IN001B EN P December 2009 PN 65329 Data Log 1 Screen FanMaster Screens and Field Descriptions C 15 The first Data Log screen is used to display detailed monthly energy and savings data calculated by FanMaster for up to five years running k JANUARY FEBRUARY nes YYYY Monthly Fan kh without Fanttaster Monthly Fan kh with Fanbtaster DASH ROAR D Monthly Average Outside Air CFhd with Fanttaster LOGGING CONTROL ey Tab
141. ublication FANM INO01B EN P December 2009 PN 65329 C 14 FanMaster Screens and Field Descriptions User City Weather Data Setup Screen The User City Weather Data Setup screen is used to create and save a climate profile for use in the configuration of FanMaster when none of the existing city climate profiles in the setup adequately match the climate profile of the city in which the FanMaster unit is installed You must enter the appropriate data in all fields on the screen for each month in the year in order to successfully create a climate profile Once your climate profile is created you can select User City in the city selection field on the first Setup screen to apply your profile This screen can only be accessed from the first Setup screen during FanMaster configuration Note A CD ROM containing climate profiles for 800 cities worldwide can be ordered from the National Oceanic and Atmospheric Administration NOAA at this link http ols nndc noaa gov plolstore plsql olstore prodspecific prodnum C00515 CDR A0001 A list of the cities provided on the CD ROM can also be viewed on the page accessed using the link above MARCH A Average Sensible Cooling Load BTUICFM Average Sensible Heating Load ATUACFM Average Latent Cooling Load ATUACFM Average Latent Heating Load OTUICF wt CANCEL CHANGES Table C M User City Weather Data Setup Screen Fields Field Name Description Jan
142. uction 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 that can cause an explosion in a hazardous environment which may lead i WARNING Identifies information about practices or circumstances 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 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 Shock Hazard labels may be located on or inside the equipment e g Rockwell Automation Allen Bradley Panel View 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 Preface Chapter 1 Chapter 2 Chapter 3 Chapter 4 Appe
143. ue is used in the estimation of savings only and therefore does not affect the actual realized savings CO Demand Setpoint ppm If the CO sensor reports a value greater 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 When the added outside air returns the interior CO level to the setpoint minus 50 ppm FanMaster 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 level which is below 1000 ppm Legal CO limits set forth by OSHA are considerably higher and vary by time of exposure Rockwell Automation recommends that you seek guidance from appropriate federal state and local regulating bodies for further information Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B 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
144. urce and wiring to the unit Once the power source and wiring has been verified set CB1 to ON You can determine the operating status of the FanMaster in the following ways e Alarm indications An alarm banner example shown below will display on the Panel View terminal to indicate a problem Refer to FanMaster Alarms on page 4 2 below for more information SUPPLY AIR TEMPERATURE OUT OF RANGE e Air Handler Unit Diagram screen on the Panel View terminal This screen provides an overview of a typical AHU configuration and current FanMaster readings If a value is out of range OOR or above a set limit or a communication fault Comm Fault has occurred in addition to the display of an alarm banner described above OOR or Comm Fault will display in place of the reading for the affected device Refer to Air Handler Unit Diagram Screen on page C 3 for more information e FanMaster Faulted indicator light This light located on the front panel of the unit will turn on when an error condition exists in FanMaster and or connected drive if installed The light will turn off when the error condition is cleared e FanMaster Faulted signal An optional dry contact output that remains closed when FanMaster is energized and is not faulted and opens when FanMaster is de energized or is faulted This output can be monitored by an external system for indication of proper FanMaster operation Refer to Figure B 2 on p
145. ure 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
146. 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 INO01B 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 o
147. vings Average energy cost of fan electricity savings since the start up or the last time the logs were cleared A higher value on this gauge indicates higher energy savings Savings MTD Current month to date electrical and cooling and heating if applicable cost savings since start up or the last time the logs were cleared Savings YTD Current year to date electrical and cooling and heating if applicable cost savings since start up or the last time the logs were cleared Savings PROJ YR Projected year to date electrical and cooling and heating if applicable cost savings since start up or the last time the logs were cleared Savings LIFE Total electrical and cooling and heating if applicable cost savings since start up or the last time the logs were cleared Next Press to view the Air Handler Unit Diagram Screen Allen Bradley FanMaster Energy Saving Package Installation Manual Publication FANM INO01B EN P December 2009 PN 65329 Air Handler Unit Diagram Screen FanMaster Screens and Field Descriptions C 3 The Air Handler Unit Diagram screen provides an overview of a typical AHU configuration and current FanMaster readings TYPICAL AHU DIAGRAM coz ppm EN MAT CSF SATF ADAR D Table C B Air Handler Unit Diagram Screen Fields Field Name Description CO2 ppm Current CO level in parts per million ppm Return Fan Current return fan p
148. wires to terminals 6 and 7 in the drive For PowerFlex 753 drives connect the damper position control wires to terminals Ao0 and Ao0 on TBI in the drive 17 Optional required when using the constant ventilation option rather than the default demand ventilation option If FanMaster will be used to override the BAS control of the outside air damper connect the damper position command signal wires to terminals 100 102 218 and 219 on TB2 in the FanMaster enclosure Important Terminals 100 102 218 and 219 on TB2 of the FanMaster unit accept a 4 20 mA signal only If the control signal is 0 10V DC or 0 135 Ohms a converter adapter must be purchased separately and be installed for both the input and output signals 18 For PowerFlex 400 style A NEMA UL Type 3R 4 amp 12 drives only jumper TB1 35 in the drive enclosure to drive signal terminal 8 19 For PowerFlex 400 drives with full feature bypass only connect terminals 61 and 162 on FanMaster TB2 to terminals 34 and 36 on TB1 in the enclosure as shown 20 For PowerFlex 400 drives with a full feature bypass and speed pot only install a new switch contact part number 800F X10 on the Hand Off Auto switch in the Auto position The switch snaps into place on the second switch level on the right side of the switch as viewed from the rear Connect a wire from PF400 terminal 11 to the top of the switch Connect a wire from the bottom of the switch to PF

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