Beruflich Dokumente
Kultur Dokumente
Mechanical Contractor/Engineer
Building Confidence in Design, Construction & Service
1133 Aladdin Avenue
San Leandro, CA 94577
1.
2.
3.
4.
5.
6.
7.
8.
B&G Pumps
....................................................................................Tab 8
1133 Aladdin Avenue San Leandro, CA 94577 (T) 510-346-3400 (F) 510-347-1308
Contractors License #120696
(800) 598-2226
1133 Aladdin Avenue
San Leandro, CA 94577-4311
Fax (510) 347-1318
TAB 1
TTA-IN-4C
18-AC32D5-4
INSTALLER'S
GUIDE
Model:
TTA030-036C,
& TTA042-072D
Library
Product Section
Product
Model
Literature Type
Sequence
Date
File No.
Supersedes
Service Literature
Unitary
Split System Cooling
TTA
Installer's Guide
4C
January 1999
SV-UN-S/S-TTA-IN-4C 1/99
TTA-IN-4B
Condensing Units
IMPORTANT This Document is customer property and is to remain with this unit. Please return to service information pack upon completion
of work.
A. GENERAL
The following instructions cover the TTA030-036C, &
TTA042-072D.
NOTICE: These outdoor units may be used with indoor
units equipped with Capillary Tube, Thermostatic Expansion Valve or the Accutron Flow Control Check
Valve (F.C.C.V.) assembly for refrigerant flow control.
Check for transportation damage after unit is uncrated. Report
promptly, to the carrier, any damage found to the unit.
To determine the electrical power requirements of the unit,
refer to the nameplate of the unit. The electrical power available must agree with that listed on the nameplate.
B. LOCATION & PREPARATION OF THE UNIT
1. The unit should be set on a level support pad at least as large
as the unit base pan.
2. The support pad must NOT be in direct contact with any
structure. The unit must be positioned a minimum of 12" from
any wall or surrounding shrubbery to insure adequate airflow.
A 30" clearance must be provided in front of control box (access
panels) & any other side requiring service access to meet
National Electrical Code. The unit must be far enough away
from any structure to prevent excess roof run-off water from
pouring directly on the unit.
3. The top discharge area must be unrestricted for at least five
(5) feet above the unit.
4. When the outdoor unit is mounted on a roof, be sure the roof
will support the units weight. Properly selected vibration
isolators are recommended to prevent transmission to the
building structure.
5. The maximum length of refrigerant lines from outdoor to
indoor unit should NOT exceed sixty (60) feet.
6. If the outdoor unit is mounted above the air handler, maximum lift should not exceed sixty (60) feet (suction line). If air
handler is mounted above the condensing unit, maximum lift
should not exceed sixty (60) feet (liquid line).
NOTE: Refer to Refrigerant Piping Guide, Pub. No. 22-3238-02.
7. Locate and install indoor coil or blower coil in accordance
with instruction included with that unit.
INSTALLER'S GUIDE
C. ACCUTRON FLOW CONTROL VALVE
If the indoor unit System Refrigerant Flow control is an
Accutron orifice and check valve assembly, an orifice size
change may be necessary.
The outdoor model determines the required orifice size. Check
the listed orifice size on nameplate of the selected outdoor
model. If the indoor unit is factory shipped with a different
orifice size, the orifice must be changed to obtain system rated
performance.
IMPORTANT: The outdoor unit is shipped with the proper
size orifice and a stick-on orifice size label in an envelope
attached to the outdoor unit. Outdoor unit nameplate will have
correct orifice size specified as BAYFCCV --- A for rated
performance.
ADAPTER
FLOW CONTROL
CHECK VALVE
(F.C.C.V.) ORIFICE
BODY
AS SHIPPED
FIELD SUPPLIED
LIQUID LINE
WARNING:
The Gas Line Service Valve is full open with a 1/4 turn counterclockwise. See Figure 4.
PAGE 2
INSTALLER'S GUIDE
3
UNIT SIDE OF
SERVICE VALVE
UNIT SIDE OF
SERVICE VALVE
LIQUID LINE
CONNECTION
HEX HEADED
VALVE SYSTEM
HEX HEADED
VALVE SYSTEM
LIQUID LINE
CONNECTION
CAP
RETAINING RING
CAUTION:
In scroll compressor applications, dome temperatures may be hot. Do not touch top
of compressor, may cause minor to severe burning.
IMPORTANT: Replace pressure tap port valve core
before attaching hoses for evacuation.
After brazing operation of refrigerant lines to both the outdoor
and indoor unit is completed, the field brazed connections must
UNIT SIDE
OF VALVE
CAP
BODY
COOLING
CORE
PAGE 3
INSTALLER'S GUIDE
5
HEAT SHIELD
24 VOLTS
WIRE SIZE
*22 AWG
30 FT.
20 AWG
100 FT.
18 AWG
150 FT
16 AWG
225 FT.
14 AWG
300 FT.
F. ELECTRICAL CONNECTIONS
Time _____________________A.M./P.M.
CAUTION:
Date ______________
By ______________________________________________________
(Electrician)
WARNING:
H. ELECTRICAL HEATERS
Electric heaters, if used, are to be installed in the air handling
device according to the instructions accompanying the air
handler and the heaters.
I. OPERATIONAL AND CHECKOUT PROCEDURES
J. OUTDOOR THERMOSTAT
An outdoor thermostat TAYSTAT250A may be field installed.
For data, see wiring diagram attached to unit and instruction
sheet packaged with outdoor thermostat.
PAGE 4
INSTALLER'S GUIDE
TTA030-036C, & TTA042-072D OUTLINE DRAWING
NOTE: ALL DIMENSIONS ARE IN MM (INCHES).
MODELS
FIG.
TTA030C
24-3/8
28-1/4
24-5/8
3/4
5/16
TTA036C
24-3/8
28-1/4
24-5/8
7/8
3/8
TTA042D
32-3/4
28-1/4
24-5/8
7/8
3/8
TTA048D
28-5/8
32-7/8
28-3/4
1-1/8
3/8
TTA060D
40-5/8
32-7/8
28-3/4
1-1/8
3/8
TTA072D
37
38-7/8
34-3/4
1-1/8
3/8
PAGE 5
INSTALLER'S GUIDE
A TYPICAL FIELD WIRING DIAGRAM FOR TTA030-072 WITH AIR HANDLER
NOTES:
1. POWER WIRING AND GROUNDING OF EQUIPMENT MUST
COMPLY WITH LOCAL CODES.
2. BE SURE POWER SUPPLY AGREES WITH EQUIPMENT
NAMEPLATE.
3. LOW VOLTAGE WIRING TO BE NO. 18 A.W.G. MINIMUM
CONDUCTOR.
4. USE COPPER CONDUCTORS ONLY.
5. POLARIZED PLUG SECTION PM-A IS ATTACHED TO HEATER
CONTROL BOX.
6. IF ODT IS NOT USED, THEN CONNECT APPROPRIATE
JUMPER FROM W1 TO W2 ON LVTB.
PAGE 6
INSTALLER'S GUIDE
CHECKOUT PROCEDURE
After installation has been completed, it is recommended that the entire system be checked against the
following list:
1. Refrigerant Line, Leak checked ..........................................................................................................
2. Suction Lines and Fittings properly insulated ......................................................................................
3. Have all Refrigerant Lines been secured and isolated properly?........................................................
4. Have passages through masonry been sealed? If mortar is used, prevent mortar from
coming into direct contact with copper tubing .....................................................................................
5. Indoor coil drain line drains freely. Pour water into drain pan .............................................................
6. Supply registers and return grilles open and unobstructed .................................................................
7. Return air filter installed ......................................................................................................................
8. Thermostat thermometer is accurate. Check against a reliable thermometer. Adjust
per instructions with thermostat ..........................................................................................................
9. Is correct speed tap being used? (Indoor blower motor) ....................................................................
[ ]
[ ]
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[
[
[
[
]
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PAGE 7
INSTALLER'S GUIDE
CHECKOUT PROCEDURE WITH MAIN POWER DISCONNECTS CLOSED (ON)
INDOOR THERMOSTAT
SWITCH SETTING
Step
No.
TO CHECK
Off
1
Cool
1
Heat
COMPONENT OPERATION
On
Indoor
Blower
Runs
Fan Switch
Auto
Outdoor
Fan
Runs
Compressor
Runs
Comp.
Sump
Heater
Sump Heat
Cooling Operation
Checking Performance
& Charge
Furnace
Heat
Comes On
X
X
Heating 2
Inform owner on how to operate system and what to expect of it. At the same time deliver Owners Use and Care Booklet.
PAGE 8
Service Facts
GAM5A0B30M21-SF-1C
Air Handler-Convertible
Model: GAM5A0B30M21SA
IMPORTANT --- This document contains a wiring diagram and service information. This is customer property and is to remain with
this unit. Please return to service information pack upon completion
of work.
GAM5A0B30M21SAA
208-230/1/60
See O.D. Specifications
Plate Fin
3 - 14
4.13
3/8
EEV
3/4 NPT
See Outline Drawing
Centrifugal
11 X 10
1
Direct - 5
See Fan Performance Table
1 - 1/3
1050
208-230/1/60
2.8
No
Throwaway
1 - 20 X 20 - 1 in.
R-410A
Brazed
3/4
3/8
HxWxD
53 x 24-1/4 x 25-3/4
51-1/2 x 21-1/4 x 21-3/4
140/132
1 These Air Handlers are A.R.I. certified with various Split System Air Conditioners
and Heat Pumps (ARI STANDARD 210/240). Refer to the Split System Outdoor
Unit Product Data Guides for performance data.
2 3/4" Male Plastic Pipe (Ref.: ASTM 1785-76)
NOTICE: Since the manufacturer has a policy of continuous product and product data
improvement, it reserves the right to change design and specifications without
notice.
2011 Trane
! WARNING
SAFETY hazard! This information is intended for use
! WARNING
LIVE ELECTRICAL COMPONENTS! During instal-
! WARNING
PRESSURIZED REFRIGERANT! SYSTEM CONTAINS
OIL AND REFRIGERANT UNDER HIGH PRESSURE. RECOVER
REFRIGERANT TO RELIEVE PRESSURE BEFORE OPENING THE
SYSTEM.
AIRFLOW PERFORMANCE
GAM5A0B30M21SAA
EXTERNAL STATIC
(in w.g)
AIRFLOW (CFM)
Speed Taps - 230 VOLTS
1282
1150
979
856
678
1279
1146
976
853
675
0.1
1238
1094
931
797
482
1232
1088
925
791
476
0.2
1186
1047
863
725
285
1177
1039
854
716
276
0.3
1141
986
803
647
88
1130
975
791
636
77
0.4
1091
935
721
555
1076
921
707
540
0.5
1033
866
649
461
1016
849
632
444
0.6
977
799
554
388
958
779
534
369
0.7
914
732
490
318
892
710
468
296
0.8
846
646
429
821
621
404
0.9
771
587
376
743
560
348
NOTES:
1. Values are with wet coil and without filters.
2. Contact your particular filter manufacturer for pressure drop data.
3. Electric heater pressure drop is negligible and is included within the airflow data.
4. Tap 1 is an continuous fan speed tap.
Without HP
BAYEAAC05BK1AA
BAYEAAC05LG1AA
Tap 3
Tap 2
BAYEAAC08BK1AA
BAYEAAC08LG1AA
Tap 4
Tap 3
BAYEAAC10BK1AA
BAYEAAC10LG1AA
Tap 4
Tap 3
BAYEABC15BK1AA
Tap 5
Tap 4
BAYEABC20BK1AA
BAYEACC25BK1AA
GAM5A0A30M21-SF-1C
WIRING DATA
GAM5A0B30M21SAA
240 VOLT
Heater
Model
No.
No.
of
Circuits
kW
No Heater
BAYEAAC05++
BAYEAAC08++
BAYEAAC10++
circuit 1
208 VOLT
BTUH
Heater
Amps
per
Circuit
Minimum
Circuit
Ampacity
Maximum
Overload
Protection
kW
2.8*
15
4.80
16400
20
29
30
7.68
26200
32
44
45
9.60
32800
40
54
9.60
49200
40
4.80
49200
20
Capacity
BTUH
Heater
Amps
per
Circuit
Minimum
Circuit
Ampacity
Maximum
Overload
Protection
2.8*
15
3.60
12300
17.3
25
25
5.76
19700
27.7
38
40
60
7.20
24600
34.6
47
50
54
60
7.20
36900
34.6
47
50
25
25
3.60
36900
17.3
22
25
Capacity
BAYEABC15++
circuit 2
Note: * Motor Amps
DISTANCE FROM BELLY BAND TO SHAFT FACE OF MOTOR FOR MINIMUM VIBRATION
BLOWER HOUSING
BELLY BAND
A
MOTOR
WHEEL
MODEL
DIM "A"
GAM5A0A18M11SA
1-1/8
GAM5A0A24M21SA
1-1/8
GAM5A0B30M21SA
1-1/8
GAM5A0B36M31SA
1-1/2
GAM5A0C42M31SA
1-1/2
GAM5A0C48M41SA
2-1/4
GAM5A0C60M51SA
2-1/4
GAM5A0A30M21-SF-1C
GAM5A0A30M21-SF-1C
Cooling OD
See unit, electric heat, and field wiring diagrams for additional
information.
Continuous Fan
Electric Heating
5. The blower motor will now run on high speed. Speed is field
selectable.
3. Switch is only operational during cooling mode. Condensate overflow is not operational during heating or defrost
modes.
GAM5A0A30M21-SF-1C
Freeze Protection
1. The EVC control has the ability to sense when the coil is
beginning to ice. When this event occurs, the contacts to
the YO circuit will open and de-energize the OD unit.
2. The indoor blower motor will continue to run to aid in defrosting the coil. After the coil has sufficiently defrosted,
the YO contacts will close and cooling operation will begin
again.
Wire Ties
GAM5A0A30M21-SF-1C
22
SW1
410
1
2
3
22
DS2
DS3
OFF
ON
OFF
ON
ON
OFF
OFF
OFF
ON
ON
OFF
ON
Model Number
GAM5A0A18M11SA
GAM5A0A24M21SA
GAM5A0B30M21SA
GAM5A0B36M31SA
GAM5A0C42M31SA
GAM5A0C48M41SA
GAM5A0C60M51SA
DS1
DS2
DS3
SW1
410
22
1
2
3
EVC STATUS
EVC STATUS LED (Non Heat Pump Systems)
Flash
1
3
NOTE: Status LED is for determining EVC control state only. Auxiliary heat status is not reported.
RED
EVC Fault
LED
OFF
1
2
3
4
5
6
7
10
11
13
NOTES:
Description
Standby
Stepper Motor coil has an open circuit or intermittent short (Replace coil)
Control has detected an internal failure (Replace EEV control, EVC)
Saturated Gas Sensor input out of range (Verify resistance, 5VDC output from control) (1)
Evaporator Gas Sensor input out of range (Verify resistance, 5VDC output from control) (1)
Stepper Motor Coil is shorted (Replace coil) (2)
Valve is not responding to a change in position. (Possible stuck valve)
High superheat (Low charge or restriction)
Low superheat (Check airflow, possible stuck valve) (3)
Condensate drain switch activated for 100 seconds (Check condensate switch and drain) (2)
Indoor frost protection activated (Check refrigerant charge and airflow) (2)
1) EEV will try to go to a safe position, cooling attempt allowed
2) K1 relay opens on EVC, Yo disabled
3) Cooling attempt allowed, 5 consecutive Y calls with same condition disables Yo
4) Faults 6, 7, & 10 may require jumper from "Test - Close" for 10 seconds to clear fault LED
7
GAM5A0A30M21-SF-1C
J2
Configuration
See Table
J4
C4
K1
U2
22.2
23.3
24.4
25.6
26.7
27.8
28.9
30.0
31.1
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40.0
41.1
42.2
43.3
44.4
45.6
46.7
47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
56.7
57.8
58.9
60.0
61.1
62.2
63.3
64.4
65.6
11024
10492
9990
9515
9065
8639
8236
7855
7493
7150
6825
6516
6224
5946
5682
5432
5194
4968
4753
4548
4354
4169
3992
3825
3665
3513
3368
3230
3098
2972
2853
2738
2629
2525
2425
2330
2239
2153
2070
1990
1.54
1.49
1.44
1.39
1.34
1.29
1.25
1.20
1.16
1.12
1.08
1.04
1.01
0.97
0.93
0.90
0.87
0.84
0.81
0.78
0.75
0.72
0.70
0.67
0.65
0.62
0.60
0.58
0.56
0.54
0.52
0.50
0.48
0.46
0.45
0.43
0.42
0.40
0.39
0.37
C9
C3
L2
C8
MH3
1-
1
2
3
R74R70
D21
R54
R8
R45
D16D17
R39
R17
C26
R57
R60 R25
C25 R29
C15
R62
C19
R63
C24 C20 L4 C14
R75 U4
R64
R55
R81
R53
R52
R76
R51
D22
C28
C27
R71
D23
X1
D24
J5
D4
C10
C11
R41
R16R35 Q6
Q2
D7
U1
C18
C34
Q1
R42
R10
R43
D2
R6R34Q5
D11
R11
R56
R47
ON
R4
R32
R37
OFF
22
R31
C22
ON
Q9
R40
R5
C37 R44
R3
D1
R15
R14
D5
Q3
C1
J1
P/N LABEL
J1
To EEV Stator
J6
L1
+12V
R83
Q7
R20
R59
C7
R19 C16
D8
C2R36
D20
Q8
Q4
R73
C13R24 R13
R27
C30
R26
R72
L3
R38
D12 C33
R69
R77
C36
C5 C6
D6
R78
R85
R28
R12
R48
C32
Q10
+VDD
R2 R7
C23
C29
R22
GND
R49
D10
C38
MH2
OPEN
TEST
CLOSE
GAM5A0A30M21-SF-1C
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
148
150
R86 R30
D9
R21
D3
R9
R46
D15
R1
MH1
Volts DC at plug J3
EVAP SAT - Brown to Brown
EVAP GAS - Black to Black
J6
To Internal
Condensate
Switch
(Optional)
Evap Saturation
Evap Gas
D13
SW2
THERMISTOR
RESISTANCE
(OHMS)
D29
SW1 OFF
410
J4
TEMP
C
D19
J7
OPEN
TEST
CLOSE
D26
R410A / R22
YO
D28
R58
R33
MOV1
R61 C21
D30
SW2
1
2
3
C31
R79
D25
SW1
D18
PG
PGC
VS D
S
VD
D
C
LR
Liteport
D14
Y1
R23
C35
J7
STATUS FAULT
FAULT
LED
J2
MH4
R18
D27
R84
STATUS
LED
TEMP
F
C12
-6.7
-6.1
-5.6
-5.0
-4.4
-3.9
-3.3
-2.8
-2.2
-1.7
-1.1
-0.6
0.0
0.6
1.1
1.7
2.2
2.8
3.3
3.9
4.4
5.0
5.6
6.1
6.7
7.2
7.8
8.3
8.9
9.4
10.0
10.6
11.1
11.7
12.2
12.8
13.3
13.9
14.4
15.0
15.6
16.1
16.7
17.2
17.8
18.3
18.9
19.4
20.0
20.6
21.1
Volts DC at plug J3
EVAP SAT - Brown to Brown
EVAP GAS - Black to Black
3.20
3.17
3.14
3.10
3.07
3.04
3.00
2.97
2.93
2.90
2.86
2.83
2.80
2.76
2.73
2.69
2.66
2.62
2.59
2.56
2.52
2.49
2.45
2.42
2.39
2.35
2.32
2.29
2.25
2.22
2.19
2.16
2.12
2.09
2.06
2.03
2.00
1.97
1.94
1.91
1.88
1.85
1.82
1.79
1.76
1.73
1.70
1.67
1.65
1.62
1.59
C17
R66
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
THERMISTOR
RESISTANCE
(OHMS)
45076
43764
42494
41266
40077
38927
37813
36736
35692
34681
33703
32755
31838
30949
30087
29253
28445
27661
26902
26166
25452
24761
24090
23440
22810
22198
21605
21030
20472
19931
19405
18896
18401
17921
17455
17002
16563
16137
15723
15320
14930
14550
14182
13824
13476
13138
12810
12491
12181
11879
11586
R82
TEMP
C
R80
TEMP F
J3
J3
See Table
Vapor Line
Sensor
(EVAP GAS)
Saturation
Sensor
(EVAP SAT)
EEV drives closed (5 seconds max) and stays closed for 1.5 minutes (90 seconds).
Note: The Close Valve Test will exit after 1.5 minutes (90 seconds) and will not reinitiate (requires a break and make to
initialize). To clear faults stored in memory, apply a jumper between Close and Test pins for 10 seconds.
EEV drives open (5 sec max) and stays open for 30 seconds.
Note: If jumper is left on pins, the OPEN VALVE TEST will be cleared after 30 seconds and will not reinitiate (requires a
break and make to reinitialize).
The Open Valve Test or Closed Valve Test can be cancelled by jumping to the opposite mode Test pin.
The system will return to normal super heat control.
9
GAM5A0A30M21-SF-1C
SUBCOOLING ADJUSTMENT
GAM5A0B30M21SAA
4A6B4030E1
4A6H5030E1
4TWB4030E1
4TWR5030E1
GAM5A0A30M21-SF-1C
10
Sensor Check
Start Here
Wait 10 minutes
11
GAM5A0A30M21-SF-1C
HIGH SUPERHEAT
Start Here
Verify that OD
condenser coils
are clean
NO
Is subcooling at the
outdoor unit
between 8-12F?
Perform
temperature
sensor check
YES
Add refrigerant
until subcooling
reaches ~10F
Recheck
superheat
NO
YES
EEV and coil are working.
Replace EVC
Check operation
Perform OPEN
VALVE test at
EVC. See page 9
YES
Does suction
pressure go
down?
YES
Perform CLOSE
VALVE test at
EVC. See page 9
YES
Does
superheat drop
below 30F?
NO
Is indoor
temperature
>85F?
NO
Ohm coil per FIG 1?
Replace coil
NO
Is ohm reading
correct?
YES
Replace EEV.
Check operation
Figure 1
4 - Phase Coil Control
4 - BLUE
3 - ORANGE
5 - BROWN (COMMON)
2 - YELLOW
6 - RED (COMMON)
1 - WHITE
GAM5A0A30M21-SF-1C
12
LOW SUPERHEAT
Start Here
Is indoor blower
running?
NO
YES
Is filter, coil,
and blower
wheel clean?
NO
Clean or replace
as needed
YES
Perform sensor
check
Perform CLOSE
VALVE test at
EVC. See page 9
Perform OPEN
VALVE test at
EVC. See page 9
Does suction
pressure rise?
Does suction
pressure drop?
NO
YES
YES
Replace EVC
Replace EVC
NO
Ohm coil per FIG1
Replace coil
NO
Is ohm reading
correct?
YES
Replace EEV.
Check operation
Figure 1
4 - Phase Coil Control
4 - BLUE
3 - ORANGE
5 - BROWN (COMMON)
2 - YELLOW
6 - RED (COMMON)
1 - WHITE
13
GAM5A0A30M21-SF-1C
FIGURE 1
NO
Does blower
wheel turn
freely?
YES
NO
Correct wiring.
Check operation
YES
NO
Is 24VAC measured
from terminal 8(G) to
terminal 9(BL) on the
fan control?
YES
GAM5A0A30M21-SF-1C
NO
YES
Replace motor.
Check operation
14
15
GAM5A0A30M21-SF-1C
Trane
6200 Troup Highway
Tyler, TX 75707
www.trane.com
For more information contact
your local dealer (distributor)
01/11
The manufacturer has a policy of continuous product and product data improvement, and it reserves the right
to change design and specifications without notice.
TAB 2
ACH550
Safety
Use of warnings and notes
There are two types of safety instructions throughout this manual:
Notes draw attention to a particular condition or fact, or give information on a
subject.
Warnings caution you about conditions which can result in serious injury or death
and/or damage to the equipment. They also tell you how to avoid the danger. The
warning symbols are used as follows:
Electricity warning warns of hazards
from electricity which can cause
physical injury and/or damage to the
equipment.
WARNING! The ACH550 adjustable speed
AC drive should ONLY be installed by a
qualified electrician.
WARNING! Even when the motor is
stopped, dangerous voltage is present at the
power circuit terminals U1, V1, W1 (L1, L2,
L3) and U2, V2, W2 (T1, T2 T3) and,
depending on the frame size, UDC+ and
UDC-, or BRK+ and BRK-.
WARNING! Dangerous voltage is present
when input power is connected. After
disconnecting the supply, wait at least 5
minutes (to let the intermediate circuit
capacitors discharge) before removing the
cover.
WARNING! Even when power is switched
off from the input terminals of the ACH550,
there may be dangerous voltage (from
external sources) on the terminals of the
relay outputs.
WARNING! When the control terminals of
two or more drives are connected in parallel,
the auxiliary voltage for these control
connections must be taken from a single
source which can either be one of the drives
or an external supply.
WARNING! Disconnect the internal EMC
filter when installing the drive on an IT
system (an ungrounded power system or a
Safety
Contents
This manual is the Operation and Maintenance Manual for the ACH550 Drives.
Complete technical details and programming information are available in the
ACH550 Users Manual, publication number 3AUA0000081823.
1. To determine the type of your drive, refer to its construction code on either:
Serial number label attached on upper part of
the chokeplate between the mounting holes.
SW:
V.2.06B
2030700001
3 PH 4863 Hz
200240 Vac
59.4 A
1 PH 463 Hz
200240 Vac
59.4 A
Output
Voltage (U2)
Current (I2n)
3 PH 0500 Hz
0U1 Vac
59.4 A
3 PH 0500 Hz
0U1 Vac
28 A
Power (Pn)
20 HP
10 HP
ACH550-UH-059A-2
S/N
2030700001
ABB Inc.
Made in USA of foreign parts
kAIC
S/N
2030700001
ACH550-UH-059A-2
Construction
code
ACH550-UH
Installation
Study these installation instructions carefully before proceeding. Failure to observe
the warnings and instructions may cause a malfunction or personal hazard.
WARNING! Before you begin read Safety on page 2.
ACH550-UH
ACH550-UH
Mounting hardware: screws or nuts and bolts, four each. The type of hardware
depends on the mounting surface and the frame size:
Frame Size
Mounting Hardware
R1R4
M5
#10
R5
M6
1/4 in
R6
M8
5/16 in
R7R8
M10
7/16
Note
IP21 / UL type 1
Kit
IP54 / UL type 12
Code (English)
Kit
Code (English)
R1
FMK-A-R1
100000982
FMK-B-R1
100000990
R2
FMK-A-R2
100000984
FMK-B-R2
100000992
R3
FMK-A-R3
100000986
FMK-B-R3
100000994
R4
FMK-A-R4
100000988
FMK-B-R4
100000996
R5
AC8-FLNGMT-R5
ACS800-PNTG01U-EN
R6
AC8-FLNGMT-R6
Note: ACH400 drives can be replaced using the original mounting holes. For R1 and
R2 frame sizes, the mounting holes are identical. For R3 and R4 frame sizes, the
inside mounting holes on the top of ACH550 drives match ACH400 mounts.
ACH550-UH
Note: Frame sizes R7 and R8 have mounting holes inside the enclosure base.
Where it is not possible to use either mounting hole at the back of the base, use an
L-bracket at the top of the enclosure to secure the cabinet to a wall or to the back of
another enclosure. Bolt the L-bracket to the enclosure using the lifting lug bolt hole
on the top of the enclosure.
2. Drill holes of appropriate size in the mounting location.
3. Remove front cover
R1R6, UL type 1
1. Remove the control panel, if attached.
2. Loosen the captive screw at the top.
3. Pull near the top to remove the cover.
R1R6, UL type 12
1. If hood is present: Remove screws (2) holding the hood in place.
2. If hood is present: Slide hood up and off of the cover.
3. Loosen the captive screws around the edge of the cover.
4. Remove the cover.
R7R8, Cabinet Door
1. To open the cabinet door, loosen the quarter-turn screws that hold the cabinet door
closed.
R7R8, Side Panels
The side panels were removed to take the cabinet off the pallet. Installation access is
easier if these panels are kept off throughout the installation.
4. Mount the drive
R1R6, UL type 1
1. Position the ACH550 onto the mounting screws
or bolts and securely tighten in all four corners.
Note: Use mounting hardware that permits fan
replacement without removal.
ACH550-UH
R1R6, UL type 12
For the UL type 12 enclosures, rubber plugs are required in the holes provided for
access to the drive mounting slots.
1. As required for access, remove the rubber plugs.
Push plugs out from the back of the drive.
2. R5 & R6: Align the sheet metal hood (not shown)
in front of the drives top mounting holes. (Attach
as part of next step.)
1, 3
5. Install wiring
WARNING! Ensure the motor is compatible for use with the ACH550. The ACH550
must be installed by a competent person. If in doubt, contact your local ABB sales or
service office.
Conduit kit
Wiring R1R6 drives with the UL type 1 Enclosure requires a conduit kit with the
following items:
conduit box
screws
cover
The kit is included with UL type 1 Enclosures.
ACH550-UH
Connection diagrams
The following diagrams show:
The terminal layout for frame size R3, which, in general, applies to frame sizes
R1R6, except for the R5/R6 power and ground terminals.
The R5/R6 power and ground terminals.
The terminal layout for R7/R8.
R1R4 (Diagram shows the R3 frame.)
J1 DIP Switches for Analog Inputs
The switch is one of two types:
ON
ON
Original
Panel Connector
X1 Digital Inputs
(and 24 V Aux. Voltage Output)
X1 Relay Outputs
Illustration of available switch
positions; not default settings
Optional Module 1
J2 DIP Switches
for RS485 Termination
J2
X1 Communications
(RS485)
J2
ON
Optional Module 2
ON
off position
Frame Sizes
R5/R6 differ.
See next page.
on position
Power Input
(U1, V1, W1)
EM1
GND
PE
X0003
ACH550-UH
R5
R6
F2
F1
F2
PE
GND
X0011
GND
Power Input
(U1, V1, W1)
F1
X0013
PE
Power Input
(U1, V1, W1)
GND
Power Output to Motor
(U2, V2, W2)
ACH550-UH
10
R7 (R8 Similar)
Motor
Terminals
Ground Lug
Bar
ACH550
Control Wires
(X1)
Input Power
Terminals
Terminal Strip
Only on
ACH550-UH
R4
R5R6
Screw
Symmetrically
grounded TN systems
(TN-S systems)
Corner grounded
TN systems
IT systems (ungrounded
or high-resistancegrounded [> 30 ohm])
EM1
EM3
EM1
EM3
F1
F2
ACH550-UH
11
Ground connections
For personnel safety, proper operation and to reduce electromagnetic emission/pickup, the drive and the motor must be grounded at the installation site.
Conductors must be adequately sized as required by safety regulations.
Power cable shields must be connected to the drive PE terminal in order to meet
safety regulations.
Power cable shields are suitable for use as equipment grounding conductors only
when the shield conductors are adequately sized as required by safety
regulations.
In multiple drive installations, do not connect drive terminals in series.
Unsymmetrically grounded networks
WARNING! Do not attempt to install or remove EM1 or EM3 screws while power is
applied to the drives input terminals.
Unsymmetrically grounded networks are defined in the following table. In such
networks, the internal connection provided by the EM3 screw (on frame sizes
R1R4 only) must be disconnected by removing EM3. If the grounding
configuration of the network is unknown, remove EM3.
Note: ACH550-UH drives are shipped with the screw removed (but included in the
conduit box).
L1
Grounded at the
mid point of a
delta leg
L1
L2
L3
L2
L3
Single phase,
grounded at an
end point
L1
Three phase
Variac without
solidly grounded
neutral
L1
L1
L2
L2
L3
L3
ACH550-UH
12
L1
L2
L3
Floating networks
WARNING! Do not attempt to install or remove EM1, EM3, F1 or F2 screws while
power is applied to the drives input terminals.
For floating networks (also known as IT, ungrounded, or impedance/resistance
grounded networks):
Disconnect the ground connection to the internal RFI filters:
Frame sizes R1R4: Remove the EM1 screw (unit is shipped with EM3
removed, see Connection diagrams on page 8).
Frame sizes R5R6: Remove both the F1 and F2 screws (see page 9).
Where EMC requirements exist, check for excessive emission propagated to
neighboring low voltage networks. In some cases, the natural suppression in
transformers and cables is sufficient. If in doubt, use a supply transformer with
static screening between the primary and secondary windings.
Do NOT install an external RFI/EMC filter. Using an RFI filter grounds the input
power through the filter capacitors, which could be dangerous and could damage
the unit.
Checking motor and motor cable insulation
WARNING! Check the motor and motor cable insulation before connecting the drive
to input power. For this test, make sure that motor cables are NOT connected to the
drive.
1. Complete motor cable connections to the motor, but NOT to the drive output
terminals (U2, V2, W2).
2. At the drive end of the motor cable, measure the insulation
resistance between each motor cable phase and Protective
Earth (PE): Apply a voltage of 1 kV DC and verify that
resistance is greater than 1 Mohm.
ACH550-UH
M
ohm
PE
13
X0007
X0005
6. Strip wires.
7. Connect power, motor, and ground wires to
the drive terminals.
7
5
4
IP2004
Note: For R5 frame size, the minimum power cable size is 25 mm2 (4 AWG). For R6
frame size, refer to Power terminal considerations R6 Frame size on page 16.
8. Route the control cables through the conduit
(not the same conduit as either input power or
motor wiring).
9. Use available secure points and tie strap
landings to permanently secure control wiring
at a minimum distance of 6 mm (1/4") from
power wiring.
10
12
IP2005
13. Strip and connect the individual control wires to the drive terminals.
14. Install the conduit box cover (1 screw).
ACH550-UH
14
R1R4
IP5013
R5, R6 1
IP5023
IP5006
4
IP5007
Note: For R5 frame size, the minimum power cable size is 25 mm2 (4 AWG). For R6
frame size, refer to Power terminal considerations R6 Frame size on page 16.
7. Route the control cables through the conduit (not
the same conduit as either input power or motor
wiring runs).
8. Use available secure points and tie strap landings to 911
permanently secure control wiring at a minimum
distance of 6 mm (1/4") from power wiring.
9. Strip the control cable sheathing and twist the
copper screen into a pig-tail.
10. Connect the ground screen pig-tail for digital and
analog I/O cables at X1-1. (Ground only at drive
end.)
11. Connect the ground screen pig-tail for RS485 cables
at X1-28 or X1-32. (Ground only at drive end.)
7
12. Strip and connect the individual control wires to the drive
terminals.
13. Install the conduit box cover (1 screw).
ACH550-UH
IP5008
15
Gnd
Input Power
Cable
Terminal Strip
Only on
ACH550-UH
BP0054
Gnd
Motor
Cable
BP0054
11. Strip and connect the individual control wires to the drive terminals.
ACH550-UH
16
Frame
Size
Earthing PE Terminal
Torque
Torque
mm2
AWG
mm
AWG
Nm
lb-ft
mm
AWG
Nm
lb-ft
R1Note 1
0.75
18
16
1.3
16
1.3
Note 1
R2
0.75
18
16
1.3
16
1.3
R3Note 1
2.5
14
25
2.7
25
2.7
R4Note 1
10
50
1/0
5.6
50
1/0
5.6
R5
16
70
2/0
15
11
70
2/0
15
11
R6
95Note 2
3/0
185
350 MCM
40
30
185
350 MCM
40
30
R7
16
185
350 MCM
40
30
R8
16
57
42
Control
Maximum Wire Size
2
All
Torque
mm
AWG
Nm
lb-ft
1.5
16
0.4
0.3
ACH550-UH
17
Note: For safety reasons the fault relay signals a fault when the ACH550 is
powered down.
X1
SCR
AI1
Analog I/O
AGND
Analog input circuit common (connected internally to chassis gnd. through 1 M).
+10 V
AI2
ON
ON
ON
Digital Inputs1
ON
for ON
ON
for ON
1
AGND
Analog input circuit common (connected internally to chassis gnd. through 1 M).
AO1
AO2
AGND
Analog output circuit common (connected internally to chassis gnd. through 1 M).
10 +24V
11
GND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
19 RO1C
20 RO1A
Relay Outputs
ON
ON
21 RO1B
22 RO2C
23 RO2A
24 RO2B
25 RO3C
26 RO3A
27 RO3B
1
2
ACH550-UH
18
You can wire the digital input terminals in either a PNP or NPN configuration.
PNP connection (source)
X1
10 +24V
11 GND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
Serial communications
Terminals 2832 provide RS485 serial communication connections used to control
or monitor the drive from a fieldbus controller.
6. Check installation
Before applying power, perform the following checks.
Check
Installation environment conforms to the drives specifications for ambient conditions.
The drive is mounted securely.
Space around the drive meets the drives specifications for cooling.
The motor and driven equipment are ready for start.
For floating networks (R1R6): The internal RFI filter is disconnected (screws EM1 & EM3 or
F1 & F2).
The drive is properly grounded.
The input power voltage matches the drive nominal input voltage range.
The input power connections at U1, V1, and W1 are connected and tightened as specified.
The input power branch circuit protection is installed.
The motor connections at U2, V2, and W2 are connected and tightened as specified.
The input power, motor and control wiring are routed through separate conduit runs.
NO power factor compensation capacitors are in the motor cable.
The control connections are connected and tightened as specified.
NO tools or foreign objects (such as drill shavings) are inside the drive.
NO alternate power source for the motor (such as a bypass connection) is connected no
voltage is applied to the output of the drive.
7. Re-install cover
ACH550-UH
19
8. Apply power
Always re-install the covers before turning power on.
WARNING! The ACH550 will start up automatically at power up, if the external run
command is on.
Apply input power. When power is applied to the ACH550, the green LED comes on.
Note: Before increasing motor speed, check that the motor is running in the desired
direction. To change rotation direction, switch motor leads as shown below.
Drive
U1
V1
W1
GND
U2
V2
W2
L1
Motor
Input L2
L3
GND
To change rotation direction,
switch motor leads
Drive
U1
V1
W1
GND
U2
V2
W2
L1
Input L2
L3
GND
Motor
FM
9. Before Start-up
The ACH550 has default parameter settings that are sufficient for many situations.
However, review the following situations. Perform the associated procedures as
appropriate.
Spin motor
When first installed and started the control panel displays a welcome screen with the
following options.
Press Exit to commission the drive as described in section Start-up by changing
the parameters individually on page 23.
Press Enter to move to the following options:
Select Commission Drive to commission the drive as described in section
Start-Up by Start-up by using the Start-Up Assistant on page 23.
Select Spin Motor to operate the motor prior to commissioning. This option
ACH550-UH
20
operates the motor without any commissioning, except entry of the motor data
as described below. Spin Motor is useful, for example, to operate ventilation
fans prior to commissioning.
Note: When using Spin Motor, the motor speed is limited to the range 1/32/3 of
maximum speed. Also, no interlocks are activated. Finally, once the drive is
commissioned, the welcome screen and this option no longer appear.
Motor data
The motor data on the ratings plate may differ from the defaults in the ACH550. The
drive provides more precise control and better thermal protection if you enter the
rating plate data.
1. Gather the following from the motor ratings plate:
Voltage
Nominal motor current
Nominal frequency
Nominal speed
Nominal power
2. Edit parameters 99059909 to the correct values.
Assistant Control Panel: The Start-Up Assistant walks you through this data entry.
Basic Control Panel: Refer to ACH550 Users Manual, for parameter editing
instructions.
Fault and alarm adjustments
The ACH550 can detect a wide variety of potential system problems. For example,
initial system operation may generate faults or alarms that indicate set-up problems.
1. Faults and alarms are reported on the control panel with a number. Note the number
reported.
2. Review the description provided for the reported fault/alarm:
Use the fault and alarm listings on pages 24 and 29 respectively, or
Press the help key (Assistant Control Panel only) while fault or alarm is displayed.
3. Adjust the system or parameters as appropriate.
ACH550-UH
21
Operation
The ACH550 HVAC control panel (ACS-CP-B) features:
Status LED
(Green when normal,
if flashing or red,
see Diagnostics.)
UP
SOFT
KEY 2
SOFT
KEY 1
DOWN
AUTO
OFF
HAND
X0201
and
or
, as
ACH550-UH
22
button.
Hand/Auto/Off To start the drive press the HAND or AUTO buttons, to stop the
drive press the OFF button.
Reference To modify the reference (only possible if the display in the upper right
corner is in reverse video) press the UP or DOWN buttons (the reference changes
immediately).
The reference can be modified in the local control mode (HAND/OFF), and can be
parameterized (using Group 11 reference select) to also allow modification in the
remote control mode.
Note: The Start/Stop, Shaft direction and Reference functions are only valid in local
control (HAND/OFF) mode.
ACH550-UH
23
ACH550-UH
24
Diagnostics
Fault listing
ACH550-UH
Fault
Code
Fault Name In
Panel
OVERCURRENT
DC OVERVOLT
DEV OVERTEMP
SHORT CIRC
RESERVED
Not used.
DC UNDERVOLT
AI1 LOSS
Analog input 1 loss. Analog input value is less than AI1FLT LIMIT (3021).
Check for and correct:
Source and connection for analog input.
Parameter settings for AI1FLT LIMIT (3021) and 3001 AI<MIN FUNCTION.
AI2 LOSS
Analog input 2 loss. Analog input value is less than AI2FLT LIMIT (3022).
Check for and correct:
Source and connection for analog input.
Parameter settings for AI2FLT LIMIT (3022) and 3001 AI<MIN FUNCTION.
25
Fault
Code
Fault Name In
Panel
MOT TEMP
10
PANEL LOSS
11
ID RUN FAIL
The motor ID run was not completed successfully. Check for and correct:
Motor connections
Motor parameters 99059909 do not match motor nameplate.
12
MOTOR STALL
Motor or process stall. Motor is operating in the stall region. Check for and
correct:
Excessive load.
Insufficient motor power.
Parameters 30103012.
14
EXTERNAL FLT
1 Digital input defined to report first external fault is active. See parameter
3003 EXTERNAL FAULT 1.
15
EXTERNAL FLT
2 Digital input defined to report second external fault is active. See parameter
3004 EXTERNAL FAULT 2.
16
EARTH FAULT
Possible ground fault detected in the motor or motor cables. The drive
monitors for ground faults while the drive is running and while the drive is
not running. Detection is more sensitive when the drive is not running and
can produce false positives.
Possible corrections:
Check for/correct faults in the input wiring.
Verify that motor cable does not exceed maximum specified length.
A delta grounded input power supply and motor cables with high
capacitance may result in erroneous error reports during non-running
tests. To disable response to fault monitoring when the drive is not
running, use parameter 3023 WIRING FAULT. To disable response to all
ground fault monitoring, use parameter 3017 EARTH FAULT.
17
UNDERLOAD
18
THERM FAIL
19
OPEX LINK
20
OPEX PWR
ACH550-UH
26
ACH550-UH
Fault
Code
Fault Name In
Panel
21
CURR MEAS
Internal fault. Current measurement is out of range. Contact your local ABB
sales representative.
22
SUPPLY PHASE
Ripple voltage in the DC link is too high. Check for and correct:
Missing mains phase.
Blown fuse.
Interaction with external input filter. Set parameter 2619 to ON.
23
ENCODER ERR
Not used (Available only with encoder and parameter Group 50).
23
ENCODER ERR
The drive is not detecting a valid encoder signal. Check for and correct:
Encoder presence and proper connection (reverse wired, loose
connection, or short circuit).
Voltage logic levels are outside of the specified range.
A working and properly connected Pulse Encoder Interface Module,
OTAC-01.
Wrong value entered in parameter 5001 PULSE NR. A wrong value will
only be detected if the error is such that the calculated slip is greater
than 4 times the rated slip of the motor.
Encoder is not being used, but parameter 5002 ENCODER ENABLE = 1
(ENABLED).
24
OVERSPEED
Motor speed is greater than 120% of the larger (in magnitude) of 2001
MINIMUM SPEED or 2002 MAXIMUM SPEED. Check for and correct:
Parameter settings for 2001 and 2002.
Adequacy of motor braking torque.
Applicability of torque control.
Brake chopper and resistor.
25
RESERVED
26
DRIVE ID
Internal fault. Configuration Block Drive ID is not valid. Contact your local
ABB sales representative.
27
CONFIG FILE
Internal configuration file has an error. Contact your local ABB sales
representative.
28
SERIAL
29
EFB CONFIG
FILE
30
FORCE TRIP
Fault trip forced by the fieldbus. See the fieldbus Users Manual.
31
EFB
32
EFB
33
EFB
34
MOTOR PHASE
1 ERR
Fault code reserved for the embedded fieldbus (EFB) protocol application.
These codes are not used as of the publication of this manual.
Fault in the motor circuit. One of the motor phases is lost. Check for and
correct:
Motor fault.
Motor cable fault.
Thermal relay fault (if used).
Internal fault.
27
Fault
Code
Fault Name In
Panel
35
OUTPUT WIRING
Possible power wiring error detected. When the drive is not running it
monitors for an improper connection between the drive input power and the
drive output. Check for and correct:
Proper input wiring line voltageis NOT connected to drive output.
The fault can be erroneously declared if the input power is a delta
grounded system and motor cable capacitance is large. This fault can be
disabled using parameter 3023 WIRING FAULT.
36
INCOMP
SWTYPE
37
CB OVERTEMP
101
SERF CORRUPT
102
RESERVED
Error internal to the drive. Contact your local ABB sales representative and
report the error number.
103
SERF MACRO
104
RESERVED
105
RESERVED
201
DSP T1
OVERLOAD
202
DSP T2
OVERLOAD
203
DSP T3
OVERLOAD
204
DSP STACK
ERROR
205
RESERVED
Error in the system. Contact your local ABB sales representative and report
the error number.
(obsolete)
206
OMIO ID ERROR
207
1000
PAR HZRPM
LIMITS
1001
PAR PFAREFNG
ACH550-UH
28
Fault
Code
1002
Fault Name In
Panel
RESERVED
(Obsolete)
1003
PAR AI SCALE
1004
PAR AO SCALE
1005
PAR PCU
1006
EXT ROMISSING
1007
PAR
FBUSMISSING
1008
PAR
PFAWOSCALAR
1009
PAR PCU1
1010
PAR PFA
OVERRIDE
Both the override mode and PFA are activated at the same time. These
modes are mutually incompatible, because PFA interlocks cannot be
observed in the override mode.
1011
PAR OVERRIDE
PARS
1012
PAR PFA IO
1013
PAR PFA IO
1014
PAR PFA IO
Fault history
For reference, the last three fault codes are stored into parameters 0401, 0412,
0413. For the most recent fault (identified by parameter 0401), the drive stores
additional data (in parameters 04020411) to aid in troubleshooting a problem. For
example, parameter 0404 stores the motor speed at the time of the fault.
ACH550-UH
29
To clear the fault history (all of the Group 04, Fault History parameters):
1. Using the control panel in Parameters mode, select parameter 0401.
2. Press EDIT.
3. Press UP and Down simultaneously.
4. Press SAVE.
Alarm listing
The following table lists the alarms by code number and describes each.
Alarm
Code
Display
Description
2001
OVERCURRENT
2002
OVERVOLTAGE
2003
UNDERVOLTAGE
2004
DIR LOCK
2005
I/O COMM
2006
AI1 LOSS
2007
AI2 LOSS
ACH550-UH
30
Alarm
Code
Description
2008
PANEL LOSS
2009
DEVICE
OVERTEMP
Drive heatsink is hot. This alarm warns that a DEVICE OVERTEMP fault
may be near.
R1R4 & R7/R8: 100 C (212 F)
R5/R6: 110 C (230 F)
Check for and correct:
Fan failure.
Obstructions in the air flow.
Dirt or dust coating on the heat sink.
Excessive ambient temperature.
Excessive motor load.
2010
MOT OVERTEMP
2011
UNDERLOAD
Motor load is lower than expected. This alarm warns that a Motor
Underload fault trip may be near. Check:
Motor and drive ratings match (motor is NOT undersized for the
drive)
Settings Group 37: USER LOAD CURVE
MOTOR STALL
Motor is operating in the stall region. This alarm warns that a Motor
Stall fault trip may be near.
2013
(note 1)
AUTORESET
This alarm warns that the drive is about to perform an automatic fault
reset, which may start the motor.
To control automatic reset, use parameter Group 31: AUTOMATIC
RESET.
2014
(note 1)
AUTOCHANGE
2015
PFA INTERLOCK
This alarm warns that the PFA interlocks are active, which means that
the drive cannot start the following:
Any motor (when Autochange is used),
The speed regulated motor (when Autochange is not used).
2016
Reserved
2017
OFF BUTTON
Note 1.
2018
(note 1)
PID SLEEP
This alarm warns that the PID sleep function is active, which means
that the motor could accelerate when the PID sleep function ends.
To control PID sleep, use parameters 40224026 or 41224126.
2012
ACH550-UH
Display
Alarm
Code
Display
31
Description
2019
ID RUN
Performing ID run.
2020
OVERRIDE
This alarm warns that the Override function is active, which may start
the motor.
2021
START ENABLE
MISSING
2022
START ENABLE
MISSING
2023
EMERGENCY
STOP
2024
ENCODER ERROR
The drive is not detecting a valid encoder signal. Check for and
correct:
Encoder presence and proper connection (reverse wired, loose
connection, or short circuit).
Voltage logic levels are outside of the specified range.
A working and properly connected Pulse Encoder Interface Module,
OTAC-01.
Wrong value entered in parameter 5001 PULSE NR. A wrong value
will only be detected if the error is such that the calculated slip is
greater than 4 times the rated slip of the motor.
Encoder is not being used, but parameter 5002 ENCODER ENABLE =
1 (ENABLED).
2025
FIRST START
2026
RESERVED
Not used.
2027
USER LOAD
CURVE
This alarm warns that the condition defined by parameter 3701 USER
LOAD C MODE has been valid longer that half of the time difined by 3703
USER LOAD C TIME.
2028
START DELAY
Shown during the Start delay. See parameter 2113 START DELAY.
Note 1. Even when the relay output is configured to indicate alarm conditions (e.g. parameter
1401 RELAY OUTPUT 1 = 5 (ALARM) or 16 (FLT/ALARM)), this alarm is not indicated by a relay output.
Maintenance
Warning! Read Safety on page 2 before performing any maintenance on the
equipment. Ignoring the safety instructions can cause injury or death.
ACH550-UH
32
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Maintenance
Application
Interval
Instruction
Check/replace R7/R8
enclosure inlet air filter
R7/R8 UL type 12
enclosures
Check every 3
months. Replace as
needed.
Check/replace R7/R8
enclosure exhaust air
filter.
R7/R8 UL type 12
enclosures
Check every 6
months. Replace as
needed.
All
Depends on the
dustiness of the
environment (every
612 months)
All
UL type 12
enclosures
Change capacitor.
See Capacitors on
page 38.
All
Heatsink
The heatsink fins accumulate dust from the cooling air. Since a dusty heatsink is less
efficient at cooling the drive, overtemperature faults become more likely. In a
normal environment (not dusty, not clean) check the heatsink annually, in a dusty
environment check more often.
Clean the heatsink as follows (when necessary):
1. Remove power from drive.
2. Remove the cooling fan (see section Drive module fan replacement on page 33).
3. Blow clean compressed air (not humid) from bottom to top and simultaneously use a
vacuum cleaner at the air outlet to trap the dust.
Note: If there is a risk of the dust entering adjoining equipment, perform the cleaning
in another room.
4. Replace the cooling fan.
5. Restore power.
ACH550-UH
33
X0021
6. Restore power.
Frame Sizes R5 and R6
X5023
6. Restore power.
X0022
ACH550-UH
34
4
3
FM
PC00018
ACH550-UH
35
3. Undo the four fastening screws at the corners of the fan frame. The screws are
through bolts with nuts on the inside of the cabinet. (Do not drop the hardware into
the drive).
PC00014
PC00018
PC00017
PC00014
PC00020
Capacitor
Velocity
Stack
PC00014
ACH550-UH
36
PC00007
PC00007
PC00009
5. Install the filter frame back to the cabinet door. Carefully align the mounting hooks to
the slots in the cabinet door. The hooks should be pointing down. Press in at the
center of the filter frame with your knee and gently press down with your hands at
the top of the frame. The filter frame will slide down approximately
3/4 inch and should be sealed securely to the door around the entire filter frame.
ACH550-UH
37
PC00021
PC00019
PC00019
PC00001
ACH550-UH
38
PC00012
PC00011
ACH550-UH
39
Installation drive
Follow the Installation instructions for the drive on page 3. Failure to observe the
warnings and instructions may cause a malfunction or personal hazard.
WARNING! Before you begin read Safety on page 2.
Installation bypass
WARNING! When the ACH550 with E-Clipse Bypass is connected to the line power,
the Motor Terminals T1, T2, and T3 are live even if the motor is not running. Do not
make any connections when the ACH550 with E-Clipse Bypass is connected to the
line. Disconnect and lock out power to the drive before servicing the drive. Failure to
disconnect power may cause serious injury or death.
Enclosure
Designation
208/240V
480V
600V
V1/V2
1 to 7.5 HP
1 to 15 HP
2 to 15 HP
V3/V4
10 to 25 HP
20 to 60 HP
20 to 60 HP
B1
1 to 7.5 HP
1 to 15 HP
2 to 15 HP
B2
10 to 25 HP
20 to 60 HP
20 to 60 HP
B3
30 to 100 HP
75 to 200 HP
75 to 150 HP
B4
N/A
250 to 550 HP
N/A
40
E-Clipse Bypass
Control Board
Terminals (X2)
Service Switch
(Optional)
Output
Terminals
Output Ground
Lug(s)
Disconnect Switch
or Circuit Breaker
Output
Ground Lug(s)
Input
Ground Lug
Output
Terminals
Service Switch
(Optional)
Input Power
Cable
Terminals
V1/V2
V3/V4
BP0054
41
ACH550
User Power
Cable Guides
E-Clipse Bypass
Control Board
Terminals X2
Service Switch
(Optional)
Motor
Terminals
Output Ground
Lug
Disconnect Switch
or Circuit Breaker
Input Power
Terminals
Input Ground
Lug(s)
B1
42
B2
ACH550 Drive
Output Ground Lug
Motor Terminals
43
ACH550 Drive
Motor Terminals
Input Power
Terminals
E-Clipse Bypass
Control Board
Terminals ( x2)
Disconnect Switch
or Circuit Breaker
Service Switch
(optional)
ACH550
Control Board
Terminals ( x1)
B4
44
Ground
Input Power
Cables
Motor
Cables
Ground
User Power
Cable Guides
45
Ground
Motor
Cables
Motor
Cables
Ground
Input Power
Cables
Input
Power
Cables
Motor Cables
Input Power
Cables
Ground
Ground
UL Type 3R Configuration (B1/B2)
46
WARNING! Check the motor and motor wiring insulation before connecting the
ACH550 to line power. Follow the procedure on page 12. Before proceeding with the
insulation resistance measurements, check that the ACH550 is disconnected from
incoming line power. Failure to disconnect line power could result in death or serious
injury.
Install the control wiring
Connect control wiring to terminal block X1 on the ACH550 control board and to
terminal block X2 on the E-Clipse Bypass control board. For more information on
these connections, refer to the following:
X1 terminal block location and terminal data are defined in the ACH550-UH
Users Manual.
X2 terminal block location is illustrated in the figures starting with Connection
diagrams Vertical E-Clipse Bypass on page 40.
X2 terminal data are provided in Basic control connections for E-Clipse HVAC
Default on page 52.
Basic connections are described in the following paragraphs. Alternate
configurations using the E-Clipse Bypass macro are described in the ACH550
Users Manual.
On Terminal Block X1 inside the ACH550, analog inputs and outputs and
additional digital input and relay output connections (AI1, AI2, AO1, AO2,
DI1DI6 and RO1RO6) are available for use.
Note: The E-Clipse Bypass control circuitry uses serial communications connections
(X1:28X1:32) inside the ACH550. These connections are not available for any
other purpose and must not be reconfigured.
47
Basic connections
The figure on page 52 shows the basic
control connections for use with the EClipse Bypass HVAC Default macro.
These connections are described in the
following paragraphs.
In typical installations, only analog input
wires connect to the ACH550 terminal
block, with other control connections
made on the E-Clipse Bypass control
board.
Digital I/O
control
terminals
EIA-485
port
control
terminals
48
Identification
Frame
Size
Disconnect
Switch
Motor
Termination
Ground
Lugs
#6
30 in-lbs
#4
35 in-lbs
208240 Volt
1
ACH550-VxR-04A6-2
R1
1.5
ACH550-VxR-06A6-2
R1
ACH550-VxR-07A5-2
R1
ACH550-VxR-012A-2
R1
ACH550-VxR-017A-2
R1
7.5
ACH550-VxR-024A-2
R2
10
ACH550-VxR-031A-2
R2
15
ACH550-VxR-046A-2
R3
20
ACH550-VxR-059A-2
R3
25
ACH550-VxR-075A-2
R4
#10
35 in-lbs
#8
40 in-lbs
#2
50 in-lbs
#1
50 in-lbs
#10
7 in-lbs
#8
7 in-lbs
#4
18 in-lbs
#1
55 in-lbs
#2
50 in-lbs
#2/0
120 in-lbs
#2
50 in-lbs
380480 Volt
1/1.5
ACH550-VxR-03A3-4
R1
ACH550-VxR-04A1-4
R1
ACH550-VxR-06A9-4
R1
ACH550-VxR-08A8-4
R1
7.5
ACH550-VxR-012A-4
R1
10
ACH550-VxR-015A-4
R2
15
ACH550-VxR-023A-4
R2
20
ACH550-VxR-031A-4
R3
25
ACH550-VxR-038A-4
R3
30
ACH550-VxR-045A-4
R3
40
ACH550-VxR-059A-4
R4
50
ACH550-VxR-072A-4
R4
60
ACH550-VxR-078A-4
R4
#10
35 in-lbs
#8
40 in-lbs
#3
50 in-lbs
#1
50 in-lbs
#10
7 in-lbs
#6
30 in-lbs
#4
35 in-lbs
#8
7 in-lbs
#4
18 in-lbs
#1
55 in-lbs
#1
70 in-lbs
#2
50 in-lbs
#2
50 in-lbs
#2/0
120 in-lbs
HP
Identification
Frame
Size
49
Disconnect
Switch
Motor
Termination
Ground
Lugs
#6
30 in-lbs
#4
35 in-lbs
500600 Volt
2
ACH550-VxR-02A7-6
R2
ACH550-VxR-03A9-6
R2
ACH550-VxR-06A1-6
R2
7.5
ACH550-VxR-09A0-6
R2
10
ACH550-VxR-011A-6
R2
15
ACH550-VxR-017A-6
R2
20
ACH550-VxR-022A-6
R3
25
ACH550-VxR-027A-6
R3
30
ACH550-VxR-032A-6
R4
40
ACH550-VxR-041A-6
R4
50
ACH550-VxR-052A-6
R4
60
ACH550-VxR-062A-6
R4
#8
62 in-lbs
#8
7 in-lbs
#4
62 in-lbs
#2
50 in-lbs
#4
18 in-lbs
#1
62 in-lbs
#1
55 in-lbs
#2/0
120 in-lbs
#2
50 in-lbs
#1
70 in-lbs
Identification
Frame
Size
Disconnect
Switch
Motor
Termination
Ground
Lugs
#6
30 in-lbs
#4
35 in-lbs
208240 Volt
1
ACH550-BxR-04A6-2
R1
1.5
ACH550-BxR-06A6-2
R1
ACH550-BxR-07A5-2
R1
ACH550-BxR-012A-2
R1
ACH550-BxR-017A-2
R1
7.5
ACH550-BxR-024A-2
R2
10
ACH550-BxR-031A-2
R2/R3
15
ACH550-BxR-046A-2
R3
20
ACH550-BxR-059A-2
R3
25
ACH550-BxR-075A-2
R4
#8
40 in-lbs
#8
7 in-lbs
#2
50 in-lbs
#1
50 in-lbs
#4
18 in-lbs
#2
120 in-lbs
#2
50 in-lbs
#1
55 in-lbs
50
HP
Identification
Frame
Size
Disconnect
Switch
Motor
Termination
Ground
Lugs
ACH550-BxR-088A-2
R4
40
ACH550-BxR-114A-2
R4
50
ACH550-BxR-143A-2
R6
60
ACH550-BxR-178A-2
R6
75
ACH550-BxR-221A-2
R6
100
ACH550-BxR-248A-2
R6
#1/0
70 in-lbs
350 MCM
274 in-lbs
2 x 250 MCM
274 in-lbs
300 MCM
275 in-lbs
2 x 250 MCM
274 in-lbs
#1
53 in-lbs
250 MCM
300 in-lbs
400 MCM
375 in-lbs
3 x #3/0
250 in-lbs
2 x 500 MCM
375 in-lbs
380480 Volt
1/1.5
ACH550-BxR-03A3-4
R1
ACH550-BxR-04A1-4
R1
ACH550-BxR-06A9-4
R1
ACH550-BxR-08A8-4
R1
7.5
ACH550-BxR-012A-4
R1
10
ACH550-BxR-015A-4
R2
15
ACH550-BxR-023A-4
R2
20
ACH550-BxR-031A-4
R3
25
ACH550-BxR-038A-4
R3
30
ACH550-BxR-045A-4
R3
40
ACH550-BxR-059A-4
R4
50
ACH550-BxR-072A-4
R4
#1
55 in-lbs
60
ACH550-BxR-078A-4
R4
#1
70 in-lbs
75
ACH550-BxR-097A-4
R4
#1/0
70 in-lbs
100
ACH550-BxR-125A-4
R5
125
ACH550-BxR-157A-4
R6
150
ACH550-BxR-180A-4
R6
200
ACH550-BxR-246A-4
R6
250
ACH550-BxR-316A-4
R8
300
ACH550-BxR-368A-4
R8
350
ACH550-BxR-414A-4
R8
400
ACH550-BxR-486A-4
R8
#8
40 in-lbs
#1
50 in-lbs
350 MCM
274 in-lbs
#8
7 in-lbs
#4
18 in-lbs
300 MCM
275 in-lbs
#6
30 in-lbs
#4
35 in-lbs
#2
50 in-lbs
#2
50 in-lbs
#2/0
120 in-lbs
#1
53 in-lbs
250 MCM
300 in-lbs
400 MCM
375 in-lbs
2 x 250 MCM
274 in-lbs
2 x 250 MCM
274 in-lbs
2 x 500 MCM
375 in-lbs
2 x 500 MCM
274 in-lbs
2 x 500 MCM
275 in-lbs
2 x 600 MCM
500 in-lbs
3 x #3/0
250 in-lbs
5 Bus bar
holes
(13/32"
bolts)
HP
Identification
Frame
Size
51
Disconnect
Switch
Motor
Termination
Ground
Lugs
#6
30 in-lbs
#4
35 in-lbs
500600 Volt
2
ACH550-BxR-02A7-6
R2
ACH550-BxR-03A9-6
R2
ACH550-BxR-06A1-6
R2
7.5
ACH550-BxR-09A0-6
R2
10
ACH550-BxR-011A-6
R2
15
ACH550-BxR-017A-6
R2
20
ACH550-BxR-022A-6
R3
25
ACH550-BxR-027A-6
R3
30
ACH550-BxR-032A-6
R4
#8
62 in-lbs
#8
7 in-lbs
#2
50 in-lbs
#1
62 in-lbs
#4
18 in-lbs
40
ACH550-BxR-041A-6
R4
50
ACH550-BxR-052A-6
R4
#1
55 in-lbs
60
ACH550-BxR-062A-6
R4
#1
75 in-lbs
75
ACH550-BxR-077A-6
R6
100
ACH550-BxR-099A-6
R6
125
ACH550-BxR-125A-6
R6
150
ACH550-Bx-R144A-6
R6
300 MCM
274 in-lbs
#2
120 in-lbs
#1/0
70 in-lbs
#1
53 in-lbs
300 MCM
275 in-lbs
250 MCM
300 in-lbs
#2
50 in-lbs
3 x #3/0
250 in-lbs
52
Description
Setting
Smoke Control (Override1) is a fixed input. Closing Digital Input 6 will place the E-Clipse Bypass in
Smoke Control mode which may reassign the function of the other Digital Inputs. Refer to the
Smoke Control (Override1) documentation.
53
54
55
3. Apply power to the E-Clipse Bypass unit. The ACH550 Control Panel display should
be illuminated. On the bypass control panel, both the display and Enabled LED
should be illuminated. If the Enabled LED is not illuminated solid green, check to see
that closed contacts or jumpers connect terminal X2:3 to X2:4 and X2:2 to X2:7 on
the bypass control board.
4. The Drive Selected LED should be illuminated. If not, press the Drive Select key to
switch to Drive mode. Leave the system in the Drive mode when proceeding to the
next step.
5. Press the Hand key on the ACH550 Control Panel. Press and hold the UP key until
the motor just starts rotating.
Note: If the ACH550 Control Panel displays an OVERCURRENT or EARTH FAULT,
disconnect and lock out power to the E-Clipse Bypass unit. Wait at least 5 minutes.
Disconnect the motor leads from the E-Clipse Bypass unit and Megger each motor
lead to ground to determine if the motor is good. Check the power leads from the
Drive / Bypass to the motor for damaged or improper wiring. If the ACH550 Control
Panel displays any other drive faults, correct the fault condition before proceeding to
the next step.
CAUTION: Check motor rotation direction as soon as the motor begins to move. If
motor does not rotate in the correct direction, shut down the drive, disconnect and
lock out power to the drive and wait five minutes. Swap any two motor output wires
(T1, T2, and T3). Incorrect motor rotation direction may cause equipment damage.
6. Increase the speed to 60 Hz or the highest safe operating speed.
7. Press the OFF key on the drive control panel. The motor should stop.
If the drive does not operate according to these steps, refer to the ACH550-UH
Users Manual.
If the drive operates according to these steps, your ACH550 with E-Clipse Bypass is
ready to use with preset or modified macro settings.
Note: The settings for ALL external serial communication between the ACH550 with
E-Clipse Bypass and any Building Automation System are configured using the
E-Clipse Bypass operator panel. DO NOT attempt to configure the external serial
communication connection using the ACH550 operator panel!
The settings for internal communication between the ACH550 and the E-Clipse
Bypass are configured at the factory and require no adjustment.
56
Note: Both the ACH550 Drive and the E-Clipse Bypass include preset application
macros. The only ACH550 Drive macro that provides the proper configuration
settings by default is the E-Clipse HVAC Default macro (9902 = 15). If any other
ACH550 drive macro or any modified setting of the E-Clipse HVAC Default macro is
used the following ACH550 Drive parameter values must be set and power cycled or
the E-Clipse Bypass will not function properly:
Parameter 9802 must be set to STD MODBUS
Parameter 1001 must be set to Comm
Parameter 1002 must be set to Comm
Parameter 1601 must be set to Comm
Parameter 1608 must be set to Comm
Parameter 5303 must be set to 76.8 kb/s
Parameter 5304 must be set to 8 EVEN 1
Parameter 5305 must be set to DCU PROFILE
Parameter 5310 must be set to 103
Parameter 5311 must be set to 104
Power must be cycled
Refer to the ACH550-UH Users Manual for programming instructions.
Note: Run motor from drive before attempting bypass operation.
System check: motor disconnected from the ACH550 with E-Clipse Bypass
If you are familiar with the E-Clipse Bypass operation, you may skip the following
section. Otherwise, after performing the system checks and setting the ACH550
Drive Start-up Data parameters, become familiar with the operation of the ACH550
Drive with E-Clipse Bypass without the motor connected as follows:
1. Disconnect and lock out power to the E-Clipse Bypass unit, wait at least five minutes
after disconnecting power.
2. Disconnect the motor from the E-Clipse Bypass unit.
3. Apply power to the E-Clipse Bypass unit by turning on the branch circuit disconnect
device and the bypass disconnect switch or circuit breaker.
4. The ACH550 Control Panel display should be illuminated. On the E-Clipse Bypass
control panel, both the display and Enabled LED should be illuminated. If the
Enabled LED is not illuminated solid green, check to see that closed contacts or
jumpers connect terminal X2:3 to X2:4 and X2:2 to X2:7 on the bypass control
board.
57
5. On the E-Clipse Bypass control panel, either the Drive Selected or Bypass Selected
LED should be illuminated. Pressing the Drive Select or Bypass Select key should
switch the bypass back and forth between the Drive mode and the Bypass mode as
indicated by the LEDs above each button. Check that the bypass control panel
switches the system between modes. Leave the system in the Bypass mode when
proceeding to the next step.
6. Check to see that pressing the:
Auto key on the bypass control panel causes the bottom line on the E-Clipse
Bypass display to indicate Bypass in Auto
Hand key on the bypass control panel generates a Motor Phase Fault.
Under normal conditions (motor connected) pressing the Hand key on the bypass
control panel causes the bottom line on the E-Clipse Bypass display to indicate
Hand #A Run
OFF key on the bypass control panel causes the bottom line on the E-Clipse
Bypass display to indicate Off Stop
7. For Steps 8 through 14, ACH550 Drive Parameter 9904 must be set to Scalar:
Freq. After successful completion of Step 13, Parameter 9904 may be set to
Vector: Speed if very specific application requirements make it necessary to use
this type of motor control. Operation using the Vector: Speed setting is
unnecessary for control of almost all fan and pump applications. Refer to the
ACH550-UH Users Manual for details on setting parameters.
8. Press the Drive Select key on the E-Clipse Bypass control panel. The Drive Select
LED should be illuminated.
9. Check to see that pressing the:
Auto key on the bypass control panel causes the E-Clipse Bypass display to
indicate Bypass in Auto
Hand key on the bypass control panel causes no change to the E-Clipse Bypass
display
OFF key on the bypass control panel causes the E-Clipse Bypass display to
indicate Bypass in Off
10. Press the HAND key on the drive control panel. Note that the top line of the control
panel display indicates HAND and run as a clockwise rotating arrow. The Drive
Run LED on the E-Clipse Bypass control panel should be illuminated.
11. Press the UP arrow on the drive control panel. Note that the speed reference
indication in the top line of the drive control panel display increases from 0.0% SP.
12. In the middle line of the drive control panel display, the output current indication
should indicate 0.0 A.
13. Press the DOWN arrow on the drive control panel until the speed and frequency
indications return to 0.0.
14. Press the OFF key on the drive control panel. Note that the bottom line of the drive
contol panel display indicates Off.
58
If the ACH550 Drive and E-Clipse Bypass operate according to these steps, and you
have familiarized yourself with their operation, disconnect and lock out power to
prepare for the next test.
WARNING! Wait at least five minutes after disconnecting power from the drive
before you attempt to service the drive. Bus capacitors in the intermediate DC circuit
must discharge before servicing the drive. Using a meter rated for 1000 VDC, check
for zero volts at:
Terminals BRK+ to GND and BRK- to GND (frame size R1/R2)
Terminals UC+ and UC- (frame size R3R8).
If the drive does not operate according to these steps, refer to the ACH550-UH
Users Manual.
3. Check jumpers and switches
The settings described in this section are factory set and, for most situations, do not
require adjustment. However, it is a good practice to review these settings to confirm
that they are appropriate for the configuration installed.
Jumper and switch locations
The figure below shows the locations of the SW1 DIP switch on the E-Clipse Bypass
control board. The function and setting of this switch is explained in the following
paragraph.
Factory
installed
jumpers
Hooked wire
race tie points
Serial Communications
Termination Resistors
SW1
ON=Terminated
OFF=Not Terminated
59
Operation
E-Clipse bypass configurations
The ACH550 with E-Clipse Bypass is an ACH550 AC adjustable frequency drive in
an integrated UL type 1, UL type 12 or UL type 3R package with a bypass motor
starter. The ACH550 with E-Clipse Bypass provides:
Disconnect switch or circuit breaker with door mounted control lever. The lever
can be padlocked in the OFF position (padlock not supplied).
Bypass starter.
Motor overload protection.
Local operator panel with indicating lights and multifunction display.
Provisions for external control connections.
Embedded communications for major BMS protocols including BACnet, Johnson
Controls International N2, Siemens Building Technologies FLN, and Modbus
Optional fieldbus adapters for connection to additional BMS protocols including
LonWorks and Ethernet
Optional drive service switch (drive input disconnect), the functional equivalent of
a three-contactor bypass arrangement.
60
The following shows the front view of the ACH550 E-Clipse Bypass vertical
configuration, and identifies the major components.
ACH550 Drive
ACH-CP-B
Control Panel
Operating Handle
for Disconnect Switch
or Circuit Breaker
BP0091
E-Clipse Bypass
The following shows the front view of the ACH550 E-Clipse Bypass standard
configurations, and identifies the major components.
ACH550 Drive with E-Clipse Bypass
ACH-CP-B
Control Panel
E-Clipse Bypass
Control Panel
Operating Handle
for Disconnect Switch
or Circuit Breaker
E-Clipse Bypass
(R8)
BP0092
61
Disconnect Switch
or Circuit Breaker
3 Phase
Input Power
ACH550
Drive
Service Switch
(Optional)
Drive Output
Contactor
Motor
3
Bypass
Contactor
Bypass control
The bypass control panel features:
Ready Indication
(Display Illuminated)
LCD Display
Down
Escape
Up
Enter
Enabled LED
Drive and Bypass
Selected/Faulted LEDs
ON/Hand Key
OFF/Reset Key
Auto Key
62
63
64
ENTER
ENTER
ENTER
ESC
or
*1601 START/STOP
1613 BP DISABLE
*1601 START/STOP
1613 BP DISABLE
ESC
ENTER
ENTER
ENTER
ENTER
ENTER
ESC
or
ESC
ESC
65
ESC
Note: In the Parameter Edit mode the current parameter value appears below the
parameter name.
Note: To view the default parameter value, press the Up/Down arrows
simultaneously. Press Enter to restore the default parameter value or press ESC to
leave the Parameter Edit mode.
Diagnostics
Fault listing
Fault
Code
Fault Name In
Panel
Fault
Possible Cause
Corrective Action
3001
RBCU is sensing
abnormal current
feedback when neither
contactor should be
energized
Defective component
on RBCU
Change RBCU
3002
BYP CNTACT
STUCK
M2 contactor indicates
it is not prepared to
move on a power up
check of the contactor
or after contact is
commanded to open
Defective Contactor
Defective RBCU
Disconnect incoming
power from unit
Check if contactor
armature moves
freely. If armature
moves freely, then
change the RBCU. If
armature does not
move freely, then
change individual
contactor (M2) or the
complete assembly
(RCSA-0x)
3003
DRV CNTACT
STUCK
M1 contactor indicates
it is not prepared to
move on a power up
check of the contactor
or after contact is
commanded to open
Defective Contactor
Defective RBCU
Disconnect incoming
power from unit
Check if contactor
armature moves
freely. If armature
moves freely, then
change the RBCU. If
armature does not
move freely, then
change individual
contactor (M1) or the
complete assembly
(RCSA-0x)
66
Fault
Code
Fault Name In
Panel
Fault
Possible Cause
Corrective Action
3004
BYPASS COIL
OPEN
Loose J8 connector
on RBCU
Loose wires on
contactor terminals A1
and/or A2
Bad Output on RBCU
Bad Contactor
Verify that J8
connector is firmly
seated.
With incoming power
disconnected, check
for tightness of A1 and
A2 terminals
Swap RBCU
Change Contactor/
Assembly
3005
DRIVE COIL
OPEN
Loose J8 connector
on RBCU
Loose wires on
contactor terminals A1
and/or A2
Bad Output on RBCU
Bad Contactor
Verify that J8
connector is firmly
seated.
With incoming power
disconnected, check
for tightness of A1 and
A2 terminals
Swap RBCU
Change Contactor/
Assembly
3006
UNDERVOLTAGE
Loose J7 connector
on RBCU unit
Loose input wiring
Incoming power
problems
Check that J7
connector is firmly
seated in RBCU
Check tightness of
incoming connections
Check Parameter
0413 to view voltage
level at time of trip
Check upstream
protection
3008
Check ACH550
manual for AI2 loss
Check ACH550
manual for AI2 loss
3009
MTR OVERLOAD
Bypass opens on
motor overload
conditions defined in
the drive
Drive Mode:
Bad Motor
Bad CTs
Bad RBCU
Bypass mode:
Bad motor
Bad CTs
Bad RBCU
Either mode:
low input voltage
Check if overload
condition exists
Drive Mode:
Refer to 550 manual
for proper
troubleshooting
techniques
Bypass Mode:
Check that J2
connector is firmly
seated in RBCU
Use clamp meter to
verify mtr current vs.
display in parameter
0101
Check input voltage
Fault
Code
Fault Name In
Panel
Fault
67
Possible Cause
Corrective Action
3010
INP PHASE A
LOSS
Loose J7 connector
Loose wiring on
Contactor assembly.
Blown upstream fuse
Check J7 connector
Check yellow wire on
input block
Check incoming
voltage, phase to
ground
3011
INP PHASE B
LOSS
Loose J7 connector
Loose wiring on
Contactor assembly.
Blown upstream fuse
Check J7 connector
Check black wire on
input block
Check incoming
voltage, phase to
ground
3012
INP PHASE C
LOSS
Loose J7 connector
Loose wiring on
Contactor assembly.
Blown upstream fuse
Check J7 connector
Check red on input
block
Check incoming
voltage, phase to
ground
3013
DRIVE 1ST
START
Fault generated if
attempting to close the
bypass contactor with
out running the
bypass in drive mode
first.
NA
3014
COIL POW
SUPPLY
Internal failure on
RBCU unit
Shorted contactor coil
Cycle power on
bypass unit. If
contactor coil is
shorted, fault 3023 or
3024 will be
generated.
If 3023 or 3024 is
generated, replace
respective contactor
If 3023 or 3024 is not
generated on power
up, replace RBCU
unit.
3016
EARTH FAULT
Declared if attempting
to close the bypass
contactor when the
drive has earth fault
declared
68
Fault
Code
Fault Name In
Panel
Fault
Possible Cause
Corrective Action
3017
MTR
UNDERLOAD
If motor power(%)
level falls below
minimum power level
establish in parameter
3003 for the time (s)
set in parameter 3002
fault will be generated.
Parameter 3003 is a
percentage of motor
power as defined in
the drive via
parameter 9909. Fault
only applies to bypass
mode
Broken belt
Check load
Reset bypass keypad
Check fault code 17
on page 25, for further
action
3018
MAX CYCLE
FAULT
Supervisory Mode
only. Declared if
bypass contactor is
closed by supervisory
control 16 times within
a 1 hour period.
Check parameters
3202-3205. Increase
time delays on
parameters 3204 and
3205
3019
DRIVE LINK
FAULT
Supervisory Mode
Only. Fault generated
if RS-485 link between
drive and bypass
stops communicating.
Bad cable/connection
between drive and
bypass.
Communication
improperly set in drive
Parameter 9802.
Application Macro
improperly set in drive
parameter 9902.
Proper seating of
cable in drive and
RBCU(connector J3)
Check drive
parameter 9802
(Modbus) and 9902
(E-Clipse)
Check drive Group 53
Follow DriveLink
recovery procedure
3020
PHASE SEQ
Sequence of 3 phase
voltage input is such
that bypass operation
will result in motor
rotation opposite of
drive forward
operation.
Phase sequence
unknown at time of
wiring
3021
PH A CURR FBK
Fault is generated
when current in Phase
A is detected and the
bypass contactor is
open
Loose CT connection
Bad RBCU
Bad CT
Check J2 connector
for proper seating
Check connector on
Current Assembly
Replace RBCU
Replace RCSA unit
3022
PH C CURR FBK
Fault is generated
when current in Phase
C is detected and the
bypass contactor is
open
Loose CT connection
Bad RBCU
Bad CT
Check J2 connector
for proper seating
Check connector on
Current Assembly
Replace RBCU
Replace RCSA unit
Fault
Code
Fault Name In
Panel
69
Fault
Possible Cause
Corrective Action
3023
BYP COIL
SHORTED
Coil characteristics
are checked only on
power up and coil
current is greater than
allowable values
Replace RBCU
Replace RCSA unit
3024
DRV COIL
SHORTED
Coil characteristics
are checked only on
power up and coil
current is greater than
allowable values
Replace RBCU
Replace RCSA unit
3027
INVALID SUB
ASM
Contactor assembly
as recorded in the
RBCU unit does not
match drive
information
communicated via 485
link
Contact ABB at
1-800-HELP-365
Option 4
3028
Incorrect
Communication
settings in Group 51 &
53.
Poor Connections
Noise on
Communication Line
3029
EFB CONFIG
FILE
Error reading
configuration file for
embedded fieldbus
Cycle Power
Replace RBCU
3030
FORCE TRIP
Overriding Control
System tripped
E-Clipse unit via
fieldbus.
Check Overriding
Control System
3031
...
3033
EFB 1...EFB 3
Check Parameters
5011, 5017 and/or
5311, 5317
3034
MTR PHASE
Internal problem
Cable problem
Motor problem
Check wiring in
E-Clipse Unit
Check motor cabling
Check Motor
Check if 3006 is
Disabled
3037
PCB TEMP
70
Fault
Code
Fault Name In
Panel
Fault
Possible Cause
Corrective Action
3038
NO DRIVE DATA
No drive data
available (Group 112)
Proper seating of
cable in drive and
RBCU (connector J3)
Check drive
parameter 9802
(Modbus) and 9902
(E-Clipse)
Check drive Group 53
Follow DriveLink
recovery procedure
then cycle power to
bypass.
3039
Non embedded
fieldbus has detected
an error in Group 51
parameters
Incorrect settings in
Group 51
Verify Group 51
parameters
3101
SFLASH
CORRUPT
Internal checksum
error
NA
Cycle power
Replace RBCU
Upgrade firmware
3102
PMAP FILE
Parameter file is
corrupt
3201
T1 OVERLOAD
T1 program cycle is
overloaded
NA
3202
T2 OVERLOAD
T2 program cycle is
overloaded
NA
3203
T3 OVERLOAD
T3 program cycle is
overloaded
NA
3204
STACK
OVERFLOW
Program cycle is
overloaded
NA
Cycle Power
Contact ABB with
information that
preceeded fault
Fault
Code
Fault Name In
Panel
Fault
71
Possible Cause
Corrective Action
3205
UNKNOWN CB
Firmware is not
compatible with
control board in
RBCU.
3206
UNKNOWN
DRIVE
Replace RBCU or
reload with most
current firmware
3207
UNKNOWN
BYPASS
NA
NA
Replace RBCU or
load most current
firmware
Contact ABB at
1-800-HELP-365
option 4
Replace RBCU or
load most current
firmware
Fault History
See page 28.
Alarm listing
The following table lists the alarms by code number and describes each.
Alarm
Code
Alarm Name In
Panel
4001
INP PHASE A
LOSS
4002
INP PHASE B
LOSS
4003
INP PHASE C
LOSS
Alarm
Alarm will occur in drive
mode. In bypass,
alarm will occur if
bypass contactor has
not closed. Unit will trip
on Fault 3010 if the
bypass contactor is
closed
Alarm will occur in drive
mode. In bypass,
alarm will occur if
bypass contactor has
not closed. Unit will trip
on Fault 3011 if the
bypass contactor is
closed
Alarm will occur in drive
mode. In bypass,
alarm will occur if
bypass contactor has
not closed. Unit will trip
on Fault 3012 if the
bypass contactor is
closed
Possible Cause
Corrective Action
Loose J8 connector
Loose wiring on
Contactor assembly.
Blown upstream fuse
Check J8 connector
Check yellow wire on
input block
Check incoming
voltage, phase to
ground
Loose J8 connector
Loose wiring on
Contactor assembly.
Blown upstream fuse
Check J8 connector
Check black wire on
input block
Check incoming
voltage, phase to
ground
Loose J8 connector
Loose wiring on
Contactor assembly.
Blown upstream fuse
Check J8 connector
Check red wire on input
block
Check incoming
voltage, phase to
ground
72
Alarm
Code
Alarm Name In
Panel
Alarm
Possible Cause
Corrective Action
4004
AUTO TRANSFER
Message is displayed
when the drive faults
and the bypass
switches to bypass
mode as configured in
Parameter 1608
Drive fault
Check drive
4005
4006
Selected by PAR
1620:
RUN ENABLE
DAMPER END
SWITCH
VALVE OPENING
PRE-LUBE CYCLE
Incorrect
Communication
settings in Group 51 &
53.
Poor Connections
Noise on
Communication Line
Run Enable condition is
not satisfied.
Bad 24v supply
Bad digital input
4007
PCB TEMP
4008
DRIVE SETUP
Incorrect parameters
settings
4009
BYPASS RUN
DELAY
Alarm is generated
when a bypass start
command is issued and
there is non zero time
value in bypass
parameter 1614
NA
NA
4010
MTR OVERLOAD
Bypass warning if
motor overload
conditions exist as
defined in the drive
Drive Mode:
Bad Motor
Bad Cts
Bad RBCU
Bypass mode:
Bad motor
Bad CTs
Bad RBCU
Either mode:
low input voltage
Drive Mode:
Refer to 550 manual
for proper
troubleshooting
techniques
Bypass Mode:
Check that J2
connector is firmly
seated in RBCU
Check input voltage
Does overload
condition exist?
Check 24 Volts on
RBCU unit
Check for 24 volts on
respective DI when
condition is satisfied
Check Parameter 0103
for status of digital input
Alarm
Code
Alarm Name In
Panel
73
Alarm
Possible Cause
Corrective Action
4011
MTR UNDERLOAD
NA
4012
BYPASS
DISABLED
NA
4013
DRIVE LINK
ERROR
4014
DRIVE TEST
Alarm is generated
when bypass
parameter 1617 is set
to enable
NA
4015
Message displayed on
initial out of box
power up sequence
NA
4016
INP VOLTAGE
LOW
NA
Loose J7 connector
Low input voltage.
Incoming voltage has
not reached at least
155 VAC within a few
seconds of powerup
4019
OVERRIDE 1
NA
4020
OVERRIDE 2
Check Parameter
0103 and 0104 for
digital input status
Check Parameter
0103 and 0104 for
digital input status
4021
Selected by PAR
1621
START ENABLE 1
VIBRATION
SWITCH
FIRESTAT
FREEZESTAT
OVERPRESSURE
VIBRATION TRIP
SMOKE ALARM
SAFETY OPEN
LOW SUCTION
PRES
NA
Check 24 Volts on
RBCU unit
Check for 24 volts on
respective DI when
condition is satisfied
Check Parameter 0103
For status of digital
input
74
Alarm
Code
Alarm Name In
Panel
Alarm
Possible Cause
Corrective Action
4022
Selected by PAR
1622
START ENABLE 2
VIBRATION
SWITCH
...
LOW SUCTION
PRES
Check 24 Volts on
RBCU unit
Check for 24 volts on
respective DI when
condition is satisfied
Check Parameter 0103
For status of digital
input
4023
Selected by PAR
1623
START ENABLE 3
VIBRATION
SWITCH
...
LOW SUCTION
PRES
Check 24 Volts on
RBCU unit
Check for 24 volts on
respective DI when
condition is satisfied
Check Parameter 0103
For status of digital
input
4024
Selected by PAR
1624
START ENABLE 4
VIBRATION
SWITCH
...
LOW SUCTION
PRES
4025
LOCAL DISABLED
4026
AUTO DISABLED
4027
COMM CONFIG
ERR
Alarm is displayed if
MODE LOCK (16.29) is
set to AUTO MODE
and the Hand or Off key
is pressed
This alarm is displayed
if MODE LOCK (1629)
is set to LOCAL MODE
and the Auto key is
pressed.
Alarm is displayed if the
drive and bypass MAC
addresses are equal or
invalid.
4028
4029
DRIVE FAULTED
Non embedded
fieldbus has detected
an error in Group 51
parameters
The drive is faulted.
E-Clipse parameters
5002(BP MAC ID) &
5302 (DV MAC ID) are
set to the same value
Check 24 Volts on
RBCU unit
Check for 24 volts on
respective DI when
condition is satisfied
Check Parameter 0103
For status of digital
input
Verify Group 51
parameters
Reset drive
75
Condition
Description
DRIVE/BYPASS?
DRIVE SELECTED
BYPASS SELECTED
SAFETIES?
OPEN
CLOSED
RUN PERMISSIVES?
OPEN
CLOSED
START REQUEST?
NOT PRESENT
PRESENT
AUTO TRANSFER?
NOT TRANSFERRED
TRANSFERRED
BYP OVERRIDE 1?
NOT ACTIVATED
ACTIVATED
Status of Override 1
BYP OVERRIDE 2?
NOT ACTIVATED
ACTIVATED
Status of Override 2
DRIVE FAULTED?
NO
YES
BYPASS FAULTED?
NO
YES
SYSTEM STARTED?
NO
YES
SYSTEM RUNNING?
NO
YES
BYPASS ALARMS?
NO ALARMS
ALARM ACTIVE
HAND/OFF/AUTO?
OFF MODE
HAND MODE
AUTO MODE
76
Error messages
#
Error Message
Description
CANT EDIT
PAR IS READ ONLY
Try to save value (=press the ENTER key in Parameter Edit State) of a readonly parameter. E.g. try to change value PAR 01.02 INPUT VOLT
CANT EDIT
WHEN STARTED
CANT EDIT
UP+DOWN ONLY
Try to change value of a reset only parameter other than zero. UP+DOWN
buttons must be pressed simultaneoulsy for requesting default value of the
PAR on the display (value zero), and after that ENTER pressed for saving it
(reset the parameter). E.g. PAR 04.01 LAST FAULT
CANT EDIT
INP VOLTAGE LOW
Input voltage too low. Changing of parameters prohibited since system cannot
save values to nv-mem w/ insufficient voltage.
CANT EDIT
PAR IS HIDDEN
Try to save value (=press the ENTER key in Parameter Edit State) of a hidden
parameter. Should not be possible. If hidden parameters are turned visible, this
message is not given.
CANT EDIT
UNDER LO-LIMIT
Try to save value which is over LO-LIMIT of the parameter. Should not be
possible when changing parameters from control panel.
CANT EDIT
UNDER HI-LIMIT
Try to save value which is over HI-LIMIT of the parameter. Should not be
possible when changing parameters from control panel.
CANT EDIT
ENUM VAL ONLY
Try to save value which is out of enumerated value list. Should not be possible
when changing parameters from control panel.
CANT EDIT
NO DEFAULT
Try to request default value (=press UP and DOWN buttons simultaneously) for
a parameter which is defined not to have a default value. Should not be
possible when changing parameters from control panel.
10
CANT EDIT
TRY AGAIN.
Maintenance
See Maintenance for the ACH550-UH on page 31.
77
ACH550-PCR/PDR
Installation
This information is unique to ACH550 input disconnect configurations (PCR or PDR).
The ACH550 with Input Disconnect is an ACH550 AC adjustable frequency drive
packaged with an input disconnect switch or circuit breaker. Refer to the Installation
instructions on page 3, for all other information. Failure to observe the warnings
and instructions may cause a malfunction or personal hazard.
WARNING! Before you begin read Safety on page 2.
WARNING! When the ACH550 with Input Disconnect is connected to the line power,
the Motor Terminals T1, T2, and T3 are live even if the motor is not running. Do not
make any connections when the ACH550 with Input Disconnect is connected to the
line. Disconnect and lock out power to the drive before servicing the drive. Failure to
disconnect power may cause serious injury or death.
1. Install wiring
WARNING!
Metal shavings or debris in the enclosure can damage electrical equipment and
create a hazardous condition. Where parts, such as conduit plates require cutting
or drilling, first remove the part. If that is not practical, cover nearby electrical
components to protect them from all shavings or debris.
Do not connect or disconnect input or output power wiring, or control wires, when
power is applied.
Never connect line voltage to drive output Terminals T1, T2, and T3.
Do not make any voltage tolerance tests (Hi Pot or Megger) on any part of the
unit. Disconnect motor wires before taking any measurements in the motor or
motor wires.
Make sure that power factor correction capacitors are not connected between the
drive and the motor.
ACH550-PCR/PDR
78
ACH550
I/O Conduit
(Top)
Ground
Lug(s)
Motor
Terminals
Gnd
Input Power
Terminals
Disconnect Switch
or Circuit Breaker
Motor
Terminals
Input Power
Terminals
I/O Conduit
(Bottom)
UL Type / NEMA 3R
Enclosures
Fan/Space Heater
Power Supply &
Control Assembly
Disconnect Switch
or Circuit Breaker
ACH550
Input Power
Terminals
Motor
Terminals
I/O Conduit
(Bottom)
Ground
Lug
ACH550-PCR/PDR
79
Ground Lug
Bar
Motor
Terminals
Input Power
Terminals
Disconnect Switch
or Circuit Breaker
ACH550-PCR/PDR
80
Input
Power
ACH550
Ground Lug
Bar
Motor
Terminals
Input Power
Terminals
Disconnect Switch
or Circuit Breaker
Input
Power
Note: The terminals on disconnect switches for the following rated ACH550-PDR
products is 7 in-lbs. Do not use a power driver or over tighten to prevent breaking
screw heads or stripping the terminal.
230 VAC
-04A6-2
-06A6-2
-07A5-2
-012A-2
-017A-2
-024A-2
-031A-2
ACH550-PCR/PDR
460 VAC
-03A3-4
-04A1-4
-06A9-4
-08A8-4
-012A-4
-015A-4
-023A-4
600 VAC
-02A7-6
-03A9-6
-06A1-6
-09A0-6
-011A-6
-017A-6
81
208/240 Volt
HP
Type Code1
Base
Circuit
Drive Breaker
Frame
UL Type/
Size
NEMA
1 &12
ACH550-PxR-04A6-2
R1
1.5
ACH550-PxR-06A6-2
R1
ACH550-PxR-07A5-2
R1
ACH550-PxR-012A-2
R1
ACH550-PxR-017A-2
R1
7.5
ACH550-PxR-024A-2
R2
10
ACH550-PxR-031A-2
R2
15
ACH550-PxR-046A-2
R3
20
ACH550-PxR-059A-2
R3
25
ACH550-PxR-075A-2
R4
30
ACH550-PxR-088A-2
R4
40
ACH550-PxR-114A-2
R4
50
ACH550-PxR-143A-2
R6
60
ACH550-PxR-178A-2
R6
75
ACH550-PxR-221A-2
R6
100
ACH550-PxR-248A-2
R6
Circuit
Breaker
UL Type
/ NEMA
3R
Disconnect
Switch
UL Type/
NEMA
1&12
#10
35 in-lbs
#10
35 in-lbs
#10
7 in-lbs
#10
7 in-lbs
#10
35 in-lbs
#10
35 in-lbs
#6
45 in-lbs
#6
45 in-lbs
#8
7 in-lbs
#8
7 in-lbs
#6
35 in-lbs
#6
35 in-lbs
#3
50 in-lbs
#3
50 in-lbs
#4
18 in-lbs
#4
18 in-lbs
#3
50 in-lbs
#3
50 in-lbs
#1
50 in-lbs
#1
50 in-lbs
#1
55 in-lbs
#1
55 in-lbs
#1/0
70 in-lbs
#1/0
70 in-lbs
#2
50 in-lbs
#2
50 in-lbs
300 MCM
275 in-lbs
300 MCM
200 in-lbs
350 MCM
274 in-lbs
300 MCM
200 in-lbs
Disconnect
Ground
Switch
Lugs
Motor
UL Type/
UL
Type/
Terminals
NEMA
NEMA
3R
1&12
Refer to
Drives
power
connection
terminals
3 x #3/0
250 in-lbs
2 x 250
MCM
274 in-lbs
2 x 250
MCM
275 in-lbs
2 x 250 MCM
274 in-lbs
2 x 250 MCM
275 in-lbs
Ground
Lugs
UL Type
/ NEMA
3R
#2/0
275 in-lbs
350 MCM
100 in-lbs
ACH550-PCR/PDR
82
480 Volt
Circuit
Base
Drive Breaker
Frame
UL
Type/
Size
NEMA
1 &12
HP
Type Code1
1/1.5
ACH550-PxR-03A3-4
R1
ACH550-PxR-04A1-4
R1
ACH550-PxR-06A9-4
R1
ACH550-PxR-08A8-4
R1
7.5
ACH550-PxR-012A-4
R1
10
ACH550-PxR-015A-4
R2
15
ACH550-PxR-023A-4
R2
20
ACH550-PxR-031A-4
R3
25
ACH550-PxR-038A-4
R3
30
ACH550-PxR-045A-4
R3
40
ACH550-PxR-059A-4
R4
50
ACH550-PxR-072A-4
R4
60
ACH550-PxR-078A-4
75
Circuit
Breaker
UL
Type/
NEMA
3R
#10
35 in-lbs
#10
35 in-lbs
#6
45 in-lbs
#6
45 in-lbs
#3
50 in-lbs
#3
50 in-lbs
#1
50 in-lbs
#1
50 in-lbs
Disconnect Disconnect
Ground
Switch
Switch
Lugs
Motor
UL Type/
UL Type/
UL
Type/
Terminals
NEMA
NEMA
NEMA
1&12
3R
1&12
#10
7 in-lbs
#10
7 in-lbs
#8
7 in-lbs
#8
7 in-lbs
#4
18 in-lbs
#4
18 in-lbs
#1
55 in-lbs
#1
55 in-lbs
R4
#1
50 in-lbs
#1
62 in-lbs
ACH550-PxR-097A-4
R4
#1/0
70 in-lbs
#1/0
70 in-lbs
100
ACH550-PxR-125A-4
R5
125
ACH550-PxR-157A-4
R6
300 MCM
275 in-lbs
300 MCM
200 in-lbs
150
ACH550-PxR-180A-4
R6
200
ACH550-PxR-246A-4
R6
2 x 250 MCM
274 in-lbs
500 MCM
274 in-lbs
250
ACH550-PxR-316A-4
R8
300
ACH550-PxR-368A-4
R8
350
ACH550-PxR-414A-4
R8
400
ACH550-PxR-486A-4
R8
450
ACH550-PxR-526A-4
R8
500
ACH550-PxR-602A-4
R8
550
ACH550-PxR-645A-4
R8
350 MCM
274 in-lbs
300 MCM
200 in-lbs
2 x 250
MCM
274 in-lbs
500 MCM
274 in-lbs
2 x 500
MCM
274 in-lbs
Ground
Lugs
UL Type
/ NEMA
3R
#10
35 in-lbs
#10
35 in-lbs
#6
35 in-lbs
#6
35 in-lbs
#3
50 in-lbs
#3
50 in-lbs
#1
50 in-lbs
#1
50 in-lbs
Refer to
Drives
power
connection
terminals
#2
50 in-lbs
3 x #3/0
250 in-lbs
#2/0
375 in-lbs
350 MCM
100 in-lbs
2 x 500 MCM
274 in-lbs
5 Bus Bar
Holes
(13/32)
3 x 400
MCM
375 in-lbs
3 x 400 MCM
375 in-lbs
ACH550-PCR/PDR
83
600 Volt
HP
Type Code1
Frame
Size
ACH550-PxR-02A7-6
R2
ACH550-PxR-03A9-6
R2
ACH550-PxR-06A1-6
R2
7.5
ACH550-PxR-09A0-6
R2
10
ACH550-PxR-011A-6
R2
15
ACH550-PxR-017A-6
R2
20
ACH550-PxR-022A-6
R3
25
ACH550-PxR-027A-6
R3
30
ACH550-PxR-032A-6
R4
40
ACH550-PxR-041A-6
R4
50
ACH550-PxR-052A-6
R4
60
ACH550-PxR-062A-6
R4
75
ACH550-PxR-077A-6
R6
100
ACH550-PxR-099A-6
R6
125
ACH550-PxR-125A-6
R6
150
ACH550-PxR-144A-6
R6
Circuit
Breaker
UL Type
/ NEMA
1 &12
Circuit
Breaker
UL
Type
/ NEMA
3R
#6
62 in-lbs
#6
62 in-lbs
#3
62 in-lbs
#3
62 in-lbs
#1
62 in-lbs
350 MCM
274 in-lbs
#1
62 in-lbs
300 MCM
275 in-lbs
Disconnect Disconnect
Switch
Switch
Motor
UL Type
UL Type
Terminals
/ NEMA
/ NEMA
3R
1&12
#8
7 in-lbs
#8
7 in-lbs
#4
18 in-lbs
#4
18 in-lbs
#1
55 in-lbs
#1
55 in-lbs
#1
62 in-lbs
#1
62 in-lbs
#1/0
70 in-lbs
#1/0
70 in-lbs
300 MCM
275 in-lbs
300 MCM
200 in-lbs
Refer to
Drives
power
connection
terminals
Ground
Lugs
UL Type
/ NEMA
1&12
Ground
Lugs
UL Type
/ NEMA
3R
#6
35 in-lbs
#6
35 in-lbs
#3
50 in-lbs
#3
50 in-lbs
#2
50 in-lbs
3 x #3/0
250 in-lbs
#2
50 in-lbs
#2/0
375 in-lbs
ACH550-PCR/PDR
84
UL Type / NEMA 3R
Enclosures
Input
Power
WARNING! Check the motor and motor wiring insulation before connecting the
ACH550 to line power. Follow the procedure on page 12. Before proceeding with the
insulation resistance measurements, check that the ACH550 is disconnected from
incoming line power. Failure to disconnect line power could result in death or serious
injury.
Note: For the remainder of the wiring (motor and control wiring) refer to page 7.
ACH550-PCR/PDR
85
Operation
This information is unique to ACH550 input disconnect configurations (PCR or PDR).
Refer to the Operation instructions on page 21 for all other information.
Input disconnect configuration
The ACH550 with Input Disconnect is an ACH550 AC adjustable frequency drive
packaged with an input disconnect switch or circuit breaker, and with a door
interlocked, external operating handle. The operating handle can be padlocked in
the OFF position (padlock not supplied). Enclosure options are UL Type 1, UL Type
12, and UL Type 3R (NEMA 1, NEMA 12, and NEMA 3R).
The following is a typical power diagram.
Disconnect Switch
or Circuit Breaker
3 Phase
Input Power
ACH550
Drive
Motor
ACH550-PCR/PDR
86
The following shows the front view of the ACH550 Drive with Input Disconnect
standard configurations, and identifies the major components.
UL Type / NEMA 1 & 12
Vertical Construction
Enclosures
Operating Handle
for Disconnect Switch
or Circuit Breaker
UL Type / NEMA 3R
Enclosures
ACH550 Drive
Control Panel with
Hinged Cover
ACH550-PCR/PDR
87
Maintenance
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB for ACH550
enclosures in addition to the intervals on page 31.
Maintenance
Configuration
Interval
Instruction
Check every 3
months. Replace
as needed.
Check/replace floor
mount enclosure inlet
air filter
Floor mount UL
Type / NEMA 12
enclosures
Check every 3
months. Replace
as needed.
Check every 3
months. Replace
as needed.
Check/replace floor
mount enclosure
exhaust air filter.
Check every 6
months. Replace
as needed.
Floor mount UL
Type / NEMA 12
enclosures
Enclosure air filter replacement UL Type / NEMA 12 hinged door wall mount
enclosures
Filter material
Material
American Air Filter (358-35-06A-12A)
Filter Type
Polykleon White 12.7 mm x 152.4 mm x 304.6 mm stk
Mounting
Screw
Filter Bracket
ACH550-PCR/PDR
88
3. Lift the filter out of the filter bracket and replace as appropriate.
4. With the filter in the filter bracket, align the hooks on the bracket with the slots in the
enclosure base, and press the hooks up into the slots.
5. Slide the filter bracket back, making sure that the hooks catch on the enclosure.
6. Replace the mounting screw. Tighten until the gasket on the bracket is about 50%
compressed.
Enclosure air filter replacement UL Type / NEMA 12 floor mount enclosures
Filter material
Enclosure Type
UL Type / NEMA 12
Inlet (door)
3AUA0000006723 (qty 1)
Outlet (roof)
3AUA0000006722 (qty 2)
Note: When installing the filter media, the white side must face the outside of the
cabinet and the colored side must face the inside of the cabinet. Refer to page 34.
Diagnostics
3AUA0000081824 REV A
Effective: 08/01/2010
ABB Inc.
16250 West Glendale Drive
New Berlin, WI 53151
USA
Telephone +1 800 752-0696
Fax
+1 262 785-0397
Internet
www.abb.us/drives
TAB 3
IM 777-5
Group: Applied Air Systems
Part Number: IM 777
Date: May 2010
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . 3
Receiving and Handling . . . . . . . . . . . . . . . . . . . . 3
Unit Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . 4
Service Clearances . . . . . . . . . . . . . . . . . . . . . . . 4
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Curb Mounting and Unit Leveling . . . . . . . . . . . . . 4
Assembling Sections . . . . . . . . . . . . . . . . . . . . . . 5
Shipping Sections . . . . . . . . . . . . . . . . . . . . . . 5
Panels, Frame Channels, and Doors . . . . . . . . . . 7
Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . 7
Frame Channel Removal . . . . . . . . . . . . . . . . 7
Access Doors and Panels . . . . . . . . . . . . . . . . 7
Fan Section Doors . . . . . . . . . . . . . . . . . . . . . 7
Injected-Foam Insulated Panels . . . . . . . . . . . 8
Field Mounting Junction Boxes and
Other Components . . . . . . . . . . . . . . . . . . . . . . . . 8
Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dampers and Hoods . . . . . . . . . . . . . . . . . . . . . . 9
Mounting Actuators . . . . . . . . . . . . . . . . . . . . . . . 9
Face and Bypass Section Mounting. . . . . . . . . . 10
Piping Vestibules . . . . . . . . . . . . . . . . . . . . . . . . 10
Piping and Coils . . . . . . . . . . . . . . . . . . . . . . . . . 10
Water Cooling Coils . . . . . . . . . . . . . . . . . . . 10
Direct Expansion Coils . . . . . . . . . . . . . . . . . 10
Steam Coils. . . . . . . . . . . . . . . . . . . . . . . . . . 11
Water Heating Coils . . . . . . . . . . . . . . . . . . . 13
Drain Pan Traps . . . . . . . . . . . . . . . . . . . . . . . . . 13
Internal Isolation Assembly Adjustment . . . . . . . 14
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . 16
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation Guidelines . . . . . . . . . . . . . . . . . . . . . . 17
Startup Checks . . . . . . . . . . . . . . . . . . . . . . . . . 17
Before Starting the Unit: . . . . . . . . . . . . . . . . . . 17
Fan Wheel Alignment . . . . . . . . . . . . . . . . . . 18
Operating Limits. . . . . . . . . . . . . . . . . . . . . . . . . 20
Fan Vibration Levels . . . . . . . . . . . . . . . . . . . . . 21
Vibration Causes . . . . . . . . . . . . . . . . . . . . . 21
Service and Maintenance . . . . . . . . . . . . . . . . . . . 22
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . 22
Ball Bearing Lubrication. . . . . . . . . . . . . . . . . . . 22
Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . 22
Fan Shaft Bearings. . . . . . . . . . . . . . . . . . . . 22
Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
VM and VP Variable Pitch Key Type Sheaves 23
LVP Variable Speed Sheaves . . . . . . . . . . . 24
MVP Variable Speed Sheaves . . . . . . . . . . . 25
Fan Drive Belt Adjustment . . . . . . . . . . . . . . 27
Front Load Filter Option. . . . . . . . . . . . . . . . . . . 28
Filter Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Winterizing Water Coils . . . . . . . . . . . . . . . . 29
Removing and Replacing Components . . . . . . . 29
Removing the Fan Section . . . . . . . . . . . . . . 29
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 31
Service and Warranty Procedure . . . . . . . . . . . . 32
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Warranty Return Material Procedure . . . . . . . . . 32
Check, Test, and Start Procedure Form . . . . . . . 33
Quality Assurance Survey Report. . . . . . . . . . . . 35
Introduction
Introduction
General Information
Unit Storage
ATTENTION
Les bords tranchants et les surfaces des bobines sont un
risque de blessure. Ne les touchez pas.
Store unit on a level surface. If air handling units are stored for
any period of time, periodically rotate the fan wheel to prevent
permanent distortion of drive components. In addition, grease
may settle in the lower part of the bearing, which can lead to
oxidation on the upper portion of the bearing surface. Keep the
fan bearings lubricated.
Nomenclature
OAH 003 G
Model
OAH = Outdoor air handler
OAC = Outdoor air component
D A C
Unit Cross Section
C = Standard unit cross section
M = Custom size cross section
Motor Location
A = Motor along side of fan housing
D = Motor downstream of belt drive plenum fan
F = Motor on inline fan
G = Motor downstream of direct drive plenum fan
T = Motor behind twin housed fans
Unit Type/Coil Position
B = Blow-thru cooling coil location
D = Draw-thru cooling coil location
H = Heating only
V = Vent only
McQuay IM 777
Mechanical Installation
Mechanical Installation
Service Clearances
Rigging
W id th
3 0 .0 0 "
W id th o f c o il s e c tio n
4 .0 0 "
W id th o f
fa n s e c tio n
3 0
.0 0
"
H e ig h t
1 2 "
5 4 "
McQuay IM 777
Mechanical Installation
Figure 4: Leveling the Unit
S h im s e c tio n s u n til
th e y a r e s tr a ig h t
a n d le v e l
S h im to p r e v e n t
d is to r tio n if w id th
is o v e r 1 0 8 "
Assembling Sections
If the unit is shipped in more than one shipping section, rig
each section into position separately. Shipping sections are
provided with a connection splice joint attached on the leaving
air side of the shipping section that seals against the frame
channel on the entering-air side of the adjoining. The splice
joint is insulated and provides an air-tight seal between two
sections once they are assembled together. Align the splice
joint to seat into the mating gasket to provide an air seal. If the
splice joint was bent during shipping or rigging, restore it to its
original position (Figure 8).
Shipping Sections
1 Caulk all assembly joints of the unitBefore joining the
1 /4 " d ia m e te r
b e a d c e n te re d
in fa c e o f
c le a r a n c e
U s e S p lic e
J o in t a s a
g u id e
McQuay IM 777
R e m o v a b le
L iftin g B r a c k e t
Mechanical Installation
Figure 7: Fasten Bottom of Section
D
Gasket
A
S p lic e C o lla r
m u s t b e a lig n e d
to s e a l to g a s k e t.
cap over the top panel flanges. Bend the ends of the
splice cap down to secure in place (Figure 9).
3 Assemble the small splice plate at the top rail to secure
5 /1 6 - 1 8 B o lt
5 /1 6 -1 8 N u t
S p lic e
P la te
McQuay IM 777
Mechanical Installation
Panels, Frame Channels, and Doors
Panel Removal
CAUTION
Sharp edges and coil surfaces are a potential injury hazard.
Avoid contact with them.
ATTENTION
Les bords tranchants et les surfaces des bobines sont un
risque de blessure. Ne les touchez pas.
CAUTION
DO NOT attempt to rotate the cup. Damage to the unit will
occur.
ATTENTION
Jam
Nuts
OPEN
Mechanical Installation
Injected-Foam Insulated Panels
Skyline air handlers now are furnished with double-wall,
injected-foam insulated panels. Foam panels are stronger,
more rigid, and lighter than panels with fiberglass insulation.
The insulation R-value is improved to 13. However, foam
insulation can burn when exposed to flame or other ignition
sources and release toxic fumes. Take care in cutting and
sealing all field-cut openings in these panels.
Prop 65Substances in fuel or from fuel combustion can cause personal injury or death,
and are known to the State of California to cause cancer, birth defects or other reproductive harm.
WARNING
La fume et les flammes peuvent
endommager le matriel et causesr des
blessures graves ou la mort.
Avant dutiliser le dispositif, obturer tous les
trous de passage de tubulures et de fils
mnags dans les panneaux intrieurs et
extrieurs au moyen dune pte base de
silicone ou dun mastic dtanchite
conduits de qualit industrielle.
Ne pas se servir dun chalumeau coupeur ni
exposer les pannequx une flamme nue
pour ne pas risquer de les endommager.
Duct Connections
Use flexible connectors on the outlet and inlet duct
connections of all units. Do not position down flow fans over
air ducts that are routed down into the building. Use a
discharge plenum when bottom connections are necessary
(Figure 13).
Figure 13: Discharge Plenum
D is c h a r g e
P le n u m
McQuay IM 777
Mechanical Installation
If the unit has a top mixing box or economizer damper or a top
duct connection, field fabricate and install flashing to divert
moisture from the connection. The flashing must lap over the
standing seams of the top panels. The flashing also must lap
over the side edges of the unit (Figure 14).
F la s h in g
D u c t
U n it to p
p a n e l
B a r r ie r
E x h a u s t
F la s h in g
F la s h in g
D u c t
Mounting Actuators
The installing contractor is responsible for the mounting of all
field-installed actuators. No provisions are made for the
location of these actuators due to the number of options and
arrangements available and the variety of specific applications.
Typically, actuators are mounted inside the cabinet. Provide
proper support for the actuator to avoid excessive stress in the
cabinet, linkage, or damper shafts.
Fresh air and return air dampers can be linked together and
driven from the same actuator if the dampers are the same size.
If the dampers are different sizes, they must be driven by
separate actuators and controlled appropriately. Exhaust
dampers are always driven by a separate actuator.
A typical rotary electric actuator can handle up to 40 sq. ft. of
damper. For pneumatic actuators, allow 5 in-lb per square foot
of damper area.
Remove screws
and panel to access
damper control shaft.
Hood
CAUTION
Maximum damper rotation is 70. Maximum shaft torque is 205
inches/pound. Greater rotation or torque can cause equipment
damage.
ATTENTION
La rotation maximale des volets est de 70. Le couple (torque)
maximum de larbre est de 205po/lb. Une plus grande rotation
(ou torque) peut endommager lquipement.
When units are ordered with exhaust hoods and intake hoods
adjacent to each other, install a field-supplied barrier to
prevent recirculation of exhaust air into the intake openings.
(Figure 16).
McQuay IM 777
Mechanical Installation
Face and Bypass Section Mounting
Note: Use glycol in water coils for outdoor air handlers. Power
failures and other mechanical issues can expose coils to
freezing temperatures.
Piping Vestibules
For units that include a piping vestibule, cut the openings for
routing the field piping as required in the field. Carefully seal
passages cut through the panels to prevent air leakage. A
single metal thickness pan is provided in the bottom of the
curb-mounted vestibule. The pan can be removed if necessary.
If holes are cut into the pan for a piping passage, seal the holes
to prevent moisture leakage (Figure 17).
Figure 17: Seal Holes for PipingCurb Mounted Units
Seal holes
cut for piping
For units with standard base rails, the vestibule is open to the
coil section; therefore, seal all holes to prevent air leakage.
Figure 18: Seal Holes for PipingStandard Base Rail Units
Seal holes
cut for piping
10
McQuay IM 777
Mechanical Installation
Steam Coils
Coils
Pitch all steam coils in units toward the return connection.
Traps
Note: Do not place steam traps outdoors.
Thoroughly mix fresh air and return air before it enters the
coil. Also, to obtain true air mixture temperatures, properly
locate temperature control elements.
As additional protection against freeze-up, install the trap
sufficiently below the coil to provide an adequate
hydrostatic head to remove condensate during an
interruption in the steam pressure. Estimate three feet for
each 1 psi of trap differential required.
McQuay IM 777
11
Mechanical Installation
Figure 19: Piping Arrangements
Float and
thermostatic trap
Check Valve
Strainer
Control valve
modulating
two position
Gate Valve
Steam main
Vacuum breaker
1/2" check valve
1/4" petcock
for continuous
air venting
Steam main
Return main
1"
min.
12" min.
1/4" petcock
for continuous
air venting
High pressure
float or bucket
trap
1" min.
12" min.
High pressure
bucket trap
Full size of
return conn.
Return main
Steam main
Vacuum breaker
1/2" check valve
Vacuum breaker
1/2" check valve
Return main
Vacuum breaker
1/2" check valve
12" min.
Return main
Return main
Full size of
return conn.
12
McQuay IM 777
Mechanical Installation
Water Heating Coils
CAUTION
Improper installation, use, or maintenance of water heating
coils can cause equipment damage. Read and follow
instructions carefully.
Pressure (P)
at the drain pan
2P
ATTENTION
Si linstallation, lutilisation ou lentretien des serpentins
de chauffage eau sont inadquats, ceci endommagera
lquipement. Lire et suivre attentivement les instructions.
2P
C le a r a n c e
McQuay IM 777
D r a in
13
Mechanical Installation
Internal Isolation Assembly
Adjustment
Top or bottom
horz. H
Downblast
H
Upblast
H
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
6.75
Fan discharge
position
Top or bottom
horz. H
Upblast
H
3.75
3.75
4.25
4.25
3.75
4.25
4.25
3.75
4.25
3.75
3.75
4.25
6.00
6.75
6.75
6.50
6.75
6.75
6.50
6.75
6.75
6.00
6.75
6.75
Adjusting bolt
6"
14
McQuay IM 777
Mechanical Installation
Figure 23: Removing Motor Behind Shipping Brackets
Unit sizes 006 - 090
S h ip p in g h o ld d o w n
r e m o v e a n d d is c a r d
( T y p ic a l 4 p la c e s )
S h ip p in g b r a c k e t
r e m o v e a n d d is c a r d
( T y p ic a l 4 p la c e s )
S e e d e ta il " A "
S p r in g h e ig h t
a d ju s tm e n t s c r e w
D im
"H "
P O S 2
P O S 3
M o to r
A ir flo w
F a n
P O S 1
P O S 4
F a n is o la to r p o s itio n n u m b e r s
S h ip p in g h o ld
d o w n s c re w
S p r in g h e ig h t
a d ju s tm e n t s c r e w
S h ip p in g
b ra c k e t
D e ta il A
McQuay IM 777
15
Electrical Installation
Electrical Installation
Wiring
DANGER
Capacitor hazardous voltage! Failure to disconnect power
and discharge capacitors before servicing will result in serious
injury or death.
Disconnect all electric power (including remote disconnects)
before servicing. Perform lockout/tagout procedures to ensure
that power can not be energized. For variable frequency drives,
or other energy storing components that have been furnished
and mounted by either McQuay, or by others, refer to the
specific manufacturers literature for allowable waiting periods
for discharge of capacitors. Verify capacitors have been
discharged using an appropriate voltmeter.
Fan Motor
Junction Box
ADVERTISSEMENT
Voltage de condesateur risquee de danger! dfaut de
dbrancher la puissance lectrique et de dcharger le
condensateur avant de faire le service, il peut en rsulter des
blessures srieuses et mme la mort.
Dbranchez toute puissance lectrique (incluant les
sectionneurs distance) avant de faire du service. Assurezvous de procder au cadenassage et la pose davis assurant
que la puissance ne peut tre rtablie.
Pour le variateur de frquence variable ou tout autre
composante pouvant accumuler de lnergie qui auraient t
fournis et installs par McQuay ou autres, se rfrer la
littrature spcifique du manufacturier donnant les priodes
spcifiques dattente ncessaires pour la dcharge du
condensateur. Vrifier que le condensateur est totalement
dcharg avec les voltmtres appropris.
CAUTION
Use copper conductors only. Failure to use copper
conductors can result in equipment damage.
ATTENTION
Utiliser du fil de cuivre seulement. La non utilisation de fil de
cuivre peut causer des dommages lquipement.
16
Conduit Entrance
(typical)
CAUTION
The base section of each cabinet has a drip pan installed
below every panel that drains to the outside frame trough. Any
holes cut through the bottom of the unit must also penetrate
the drip pan. If holes are cut in the drip pan, seal them to
prevent moisture leakage.
ATTENTION
Chaque cabinet est muni dune base avec une panne
dgouttement installe en-dessous de chaque panneau qui
vacuera leau vers la gouttire extrieure. Tous les trous
percs au bas de lunit doivent pntrer la panne
dgouttement. Sil y a des trous dans la panne
dgouttement, les sceller pour empcher les fuites deau.
McQuay IM 777
Operation Guidelines
Operation Guidelines
Startup Checks
ATTENTION
When performing startup and service, always take thorough
safety precautions. Only trained, experienced personnel should
perform these functions.
WARNING
Rotating fan. Can cause severe injury or death. Before
servicing fans, lockout and tag out power.
AVERTISSEMENT
Ventilateur en rotation. Peut causer des blessures svres
ou mme la mort. Avant deffectuer lentretien des ventilateurs,
bloquer et couper la tension.
WARNING
Fire/electric shock hazard. Can cause property damage,
personal injury or death. Wire fan power supply and ground
motor frame in accordance with local electric codes.
clean.
3 Check that all electrical work is complete and properly
AVERTISSEMENT
Risques dincendie et dlectrocution pouvant causer des
dommages matriels, des blessures et mme la mort.
Lalimentation lectrique du moteur du ventilateur de mme
que la mise la terre du chssis du moteur doivent tre faits
conformment aux codes dinstallations lectriques en
vigueur.
WARNING
Fan motor requires overload protection. Failure to provide
motor overload protection can result in fire, property damage,
electric shock, personal injury, or death. Connect motor to an
overload protective device rated in compliance with local
electric codes.
AVERTISSEMENT
Risques dincendie et dlectrocution pouvant causer des
dommages matriels, des blessures et mme la mort.
Connecter au moteur du ventilateur lectrique un dispositif de
protection contre les surcharges conforme aux codes
dinstallations lectriques en vigueur.
terminated.
4 Check that all electrical connections are tight and that the
ADVERTISSEMENT
Les dommages dus des attaches installes de faon
inapproprie reprsentent un dmarrage inadquat et un
abus dquipement. Ceci nest pas couvert par la garantie.
CAUTION
Do not overheat fan motor. High air temperatures in the fan
section can cause the fan motor to burnout. On draw-through
air handlers or air handlers with the fan section down the air
stream from the heating section, the discharge air temperature
of the heating section must not exceed 104F (40C).
tight.
3 Check that the condensate drain is trapped.
4 Rotate the shaft by hand to be sure it is free.
Fan Startup:
Start and run fan. Observe the rotation. If the fan operates
backward, reverse two legs of the three-phase motor
connections.
McQuay IM 777
17
Operation Guidelines
Note: Variable pitch fan drives usually are provided for
operation in the mid-speed adjustment range. However,
the drives usually ship with the adjustment opened up for
minimum fan speed. Adjust the drives for the proper
airflow. See Fan Drive page 23.
After the First 48 Hours of Operation:
C (in) C (mm)
9x4
0.25
6.35
9x7
0.13
3.30
B
A
E q u a l s p a c in g
a ll a r o u n d
0.24
6.10
20 (Class 1 & 2)
10.41
0.25
6.35
10
0.22
5.59
12
0.35
8.89
30 (Class 1 & 2)
0.47
11.94
15
0.44
11.18
33 (Class 1 & 2)
0.50
12.70
18
0.25
6.35
36 (Class 1 & 2)
0.75
19.05
20 (Class 1 & 2)
0.73
8.54
14.99
14.22
C (in) C (mm)
9x9
Diameter (in)
Note:
0.47
11.94
25 (Class 1 & 2)
11.94
EQUALLY SPACED
AROUND DIAMETER
B
(in)
B
(mm)
A
(mm)
A
(in)
B
(mm)
13.22 4.56
116
0.21
183
0.31
7.87
14.56 5.06
129
0.21
195
0.33
8.38
16.18 5.62
17.69 6.90
143
0.21
217
0.31
7.87
175
0.22
241
0.63 16.00
21.56 7.59
193
0.24
266
0.39
9.91
24.00 8.45
215
0.23
298
0.38
9.65
36.50 12.78
325
0.38
9.65
40.25 14.31
363
0.50 12.70
Dia.
Note:
A
(in)
A
(in)
In le t
F u n n e l
18
W h e e l
In le t
F u n n e l
13
0.25
0.91
3.50
15
0.25
0.91
3.50
16
0.25
0.91
3.50
18
0.38
0.86
3.88
20
0.42
1.11
3.88
22
0.45
1.11
3.88
24
0.51
1.11
3.88
27
0.55
1.36
4.50
30
0.62
1.36
4.50
33
0.55
1.50
5.00
36
0.63
1.50
5.00
McQuay IM 777
Operation Guidelines
Figure 29: Wheel-to-Inlet Funnel Relationship40 to 60
Plenum Fans
Cross Section Reference
A
FUNNEL END TO FAN
WHEEL OPENING
EQUALLY
SPACED AROUND
DIAMETER
27
3/8
19.2
22
30
1/2
41.7
55
33
1/2
41.7
55
36
1/2
41.7
55
40
1/2
41.7
55
44
1/2
41.7
55
49
1/2
41.7
55
54
1/2
41.7
55
60
3/4
115
150
40
0.82
2.00
4.88
44
0.91
2.25
5.50
49
1.00
2.50
5.50
54
1.10
2.50
5.50
60
1.23
3.00
5.50
Size
Overlap
150
.375
165
.438
182
.562
200
.625
222
.688
245
.750
270
.812
300
.875
330
1.000
365
1.125
402
1.250
445
1.375
Torque (ft.-lb)
Fan Size
Setscrew Size
Aluminum
Steel
Set screw
Diameter (in)
Minimum torque
ft/lbs
kg/m.
13
3/8
19.2
N/A
15
3/8
19.2
N/A
1/4
5.5
.76
1/16
10.5
1.45
16
3/8
19.2
N/A
18
3/8
19.2
N/A
3/8
19.0
2.63
29.0
4.01
20
3/8
19.2
N/A
7/16
22
3/8
19.2
N/A
1/2
42.0
5.81
N/A
5/8
92.0
12.72
24
McQuay IM 777
3/8
19.2
19
Operation Guidelines
Operating Limits
Do not exceed the operating limits in Table 10. A fan wheel
operated beyond the rpm and temperature limits shown can
94
97
99
10.62
12.62
15
18
20
22.25
N/A
2189
2223
1934
1614
1328
1155
1050
944
24.50
858
2700
2854
2896
2518
2091
1725
1450
1200
1030
910
Diameter
13.22
14.56
16.19
19.69
21.56
24.00
3000
3000
2300
2000
1700
1500
4335
3918
3457
2858
2427
2255
Airfoilhoused
150
.5
14
AF
750
800
850
900
1000
22
3.
1
AF
100
90
80
70
60
50
40
35
30
1500
450
500
550
600
650
700
750
800
850
900
1000
400
350
250
100
90
80
300
150
19
6.
1
AF
4500
00
0.
2
FC
69
9.
1
AF
4000
FC
56
1.
2
AF
3500
.
22
3000
38
.0
4
F2
1500
200
200
Torque (inlb)
250
Torque (inlb)
FC
FC 36.
0
FC 33. 0
00
3
0.
FC
25
27
.6
FC
2
25
.0
0
400
350
300
450
400
350
300
250
200
2500
500
2000
20
22.38
25
27.62
30.25
33
36
1010
930
790
690
650
600
560
1281
1178
1011
910
835
763
715
Airfoilhoused
Diameter
20
22.25
24.5
27
30
33
36.5
2077
1875
1691
1479
1328
1209
1073
2703
2413
2199
1928
1730
1579
1401
300
2
FC
200
Torque (inlb)
5
4.
2
2.
2
FC
1500
.0
0
C2
00
.
18
150
FC
00
.
15
FC
100
90
80
70
60
62
2.
1
FC
Torque (inlb)
250
25
0.
4
AF
1000
900
800
700
600
500
400
350
300
250
200
50
8.
3
AF
.0
3
F3
00
0.
3
AF
00
0
.5
24 2.25
F
A F2
00
0.
A
2
AF
7.
2
AF
150
50
20
3000
2500
2000
1500
550
600
650
700
750
800
850
900
1000
2000
1500
500
550
600
650
700
750
800
850
900
1000
450
400
350
100
McQuay IM 777
Operation Guidelines
Table 12: Operating LimitsPlenum Fans
Fan operating limits
Plenum fans
Diameter
Class
Maximum rpm
13.5
15
16.5
18.25
20
22.25
24.5
27
30
33
36.5
40.25 44.50
2
49
54.25
60
986
891
75
75
3,909 3,468 2,820 2,930 2,674 2,403 2,183 1,860 1,783 1,620 1,465 1,329 1,202 1,091
Maximum motor HP
7.5
10
15
15
15
20
25
30
40
40
50
60
75
75
18.25
20
22.25
24.5
27
30
33
36.5
40.25
44.50
49
54.25
2727
2488
2236
2041
1835
1665
1476
1330
1208
1072
973
880
3409
3111
2796
2551
2294
2082
1846
1662
1510
1340
1216
1100
Diameter
9x9
10.62
12.62
15
18.12
20
Maximum rpm
2575
2400
2000
1700
1400
1200
Maximum HP
10
15
15
30
40
40
Twin fans
54
2
4000
49
0
3000
44
5
Note:
40
2
36
5
1000
900
800
700
Vibration
800 or less
801 or greater
600
Vibration Causes
500
1 Wheel imbalance.
33
0
Torque
(in-lb
)
Torque
(lb./in.)
2000
400
270
300
245
200
3 Drive faulty.
a Variable pitch sheavesAxial and radial runout of
3000
2000
1500
700
800
900
1000
600
500
400
300
200
100
McQuay IM 777
21
Periodic Maintenance
1 Check all moving parts for wear every six months.
2 Check bearing collar, sheave, and wheel hub setscrews,
Motor Bearings
Supply and return fansSupply and return fan motors
should have grease added after every 2000 hours of operation.
Using the following procedure, relubricate the bearings while
the motor is warm, but not running. Use one of the greases
shown in Table 15.
Table 15: Recommended Lubricants and Amounts for Fan
Motor Bearings
Mfr. Grease
NEMA Size
Amount to Add
(oz.)
Texaco, Polystar
or
Polyrex EM (Exxon Mobile)
or
Rykon Premium #2
or
Penzoil Pen 2 Lube
56 to 140
140
180
210
250
280
320
360
400
440
0.08
0.15
0.19
0.30
0.47
0.61
0.76
0.81
1.25
2.12
CAUTION
For safety, stop rotating equipment. Add one half of the
recommended amount shown in Figure 18. Start bearing,
and run for a few minutes. Stop bearing and add the second
half of the recommended amount. A temperature rise,
sometimes 30F (1C), after relubrication is normal. Bearing
should operate at temperature less than 200F (94C) and
should not exceed 225F (107C) for intermittent operation.
For a relubrication schedule, see Table 16. For applications
that are not in the ranges of the table, contact McQuay.
CAUTION
The tables below state general lubrication
recommendations based on our experience and are
intended as suggested or starting points only. For best
results, specific applications should be monitored regularly
and lubrication intervals and amounts adjusted accordingly.
Table 16: Relubrication Intervals
(Use NLGI #2 Lithium or Lithium Complex Grease)
Speed
Temperature
Cleanliness
Relub. intervals
Up to 120F
100 rpm
Clean
6 to 12 months
(50C)
Up to 150F
500 rpm
Clean
2 to 6 months
(65C)
Up to 210F
2 weeks to 2
1000 rpm
Clean
months
(100C)
Over 210F
(100C) to
1500 rpm
Clean
Weekly
250F (120C)
Up to 150F
Above 1500 rpm
Dirty/wet
1 week to 1 month
(65C)
Over 150F
Max catalog rating (65C) to 250F
Dirty/wet
Daily to 2 weeks
(120C)
Above 250F
Contact Browning
(120C)
Temperature
Base
Thickener
NLGI
grade
Texaco,
Premium RB
Mobile, AW2
30 to 350F
(34 to 177C)
40 to 437F
(40 to 175C)
68 to 356F
(50 to 180C)
60 to 450F
(51 to 232C)
Parafinic
mineral oil
Mineral oil
Lithium
Lithium
Synthetic
Lithium
Synthetic
Lithium
40 to 300F
(40 to 149C)
Mineral oil
Lithium
2 Insert a grease fitting into the upper hole and add clean
plugs.
Note: Specific greasing instructions are located on a tag
attached to the motor. If special lubrication instructions
are on the motor, they supersede all other instructions.
22
Mobile, SHC
100
Chevron,
Altiplex
Synthetic
Exxon, ronex
MP
Note:
Temperature ranges over 225F are shown for lubricants only. High
temperature applications are not suitable for standard air handler
components.
McQuay IM 777
OZ.
0.03
0.10
0.15
0.20
0.30
0.50
0.85
1.50
Shaft Size
20 mm
25-30 mm
35-40 mm
45-50 mm
55-60 mm
65-70 mm
75-80 mm
85-105 mm
Grams
0.85
2.84
4.25
5.67
8.51
15.59
24.10
42.53
Adjusting
1 Loosen setscrews B and C in moving parts of sheave and
pull out external key E. (This key projects a small
amount to provide a grip for removing.)
2 To adjust sheave pitch diameter for desired speed, open
Fan Drive
WARNING
Before servicing fans, lock out and tag out all power to the
unit. Fans or belts can cause severe personal injury or death.
sheave.
AVERTISSEMENT
Avant de faire le service sur les ventilateurs,couper et
indiquer que le courant est coup. Les ventilateurs ou les
courroies peuvent causer des blessures personnelles graves
ou entraner la mort.
WARNING
Do not open the hinged access door and screw-fastened
access panels while the unit is operating. Moving parts and
strong suction forces can cause severe personal injury or
death.
AVERTISSEMENT
Single Groove
D
C
Key E projects
to provide a grip
for removal.
Do not operate
sheeves with flange
projecting beyond
the hub end.
B
Two Groove
D
Mounting
1 Mount all sheaves on the motor or driving shaft with the
setscrews A toward the motor.
McQuay IM 777
23
10 Before starting the drive, ensure that all keys are in place
and all setscrews and all capscrews are tight. Check and
retighten all screws and retension belts after
approximately 24 hours of service.
Adjusting
1 Slack off belt tension if belts have been installed.
2 Loosen setscrews D.
4 Remove key F.
c Remove key F.
alignment and the shafts are parallel. When aligning twogroove sheaves, allow room between the sheave and
motor to access capscrews E.
5 Insert key C between the sheave and the shaft and tighten
setscrew A securely.
7 Replace key F.
8 Tighten setscrews D and capscrews E.
replacing them make sure that the inner and outer flanges
are open from the closed position by the same amount as
the other flange. Determine this by accurately measuring
the top width of the grooves.
7 Insert key F.
and all setscrews and all capscrews are tight. Check and
retighten all screws and retension belts after
approximately 24 hours of operation.
A
E
A
F
D
B
Section A-A
24
Section A-A
McQuay IM 777
into the three holes that are located 120 apart on the
ring.
Mounting
1 Verify both driving and driven sheaves are in alignment
and the shafts are parallel. The centerline of the driving
sheave must be in line with the centerline of the driven
sheave. See Figure 38, page 26.
2 Verify that all setscrews are torqued to the values shown
1/420NC
Seating torque
Seating torque
Seating torque
Seating torque
Length (L)
Seating torque
(inlbs)
(inlbs)
(inlbs)
(inlbs)
(inlbs)
(inlbs)
(inlbs)
150
12.5
100
87
7.3
3/16
50
5/1611NC
305
25.4
200
165
13.8
1/4
90
3/816NC
545
45.4
350
290
24.2
1/4, 5/16
150, 250
1/213NC
1300
108.3
N/A
620
51.7
N/A
N/A
5/811NC
N/A
N/A
N/A
1225
102.1
N/A
N/A
McQuay IM 777
25
Bearing
Center lines
must coincide
Motor
Adjustable
Sheave
Must be
parallel
F ix e d
C e n te r - F la n g e
( 2 ) L o c k in g
S e ts c re w s "A "
F la th e a d S o c k e t S c r e w s
(D o N o t R e m o v e )
S p lit T a p e r
B u s h in g
C a p s c re w s
(D o N o t R e m o v e )
26
S ta tio n a r y
E n d - F la n g e
O u te r
L o c k in g - R in g
In n e r L o c k in g - R in g
( 3 ) H o le s fo r
S p a n n e r W re n c h
o r D r ift
McQuay IM 777
Moving belt and fan can cause severe personal injury or death.
During installation and filter maintenance:
Verify that the belt and fan guards on plenum fan units are
always in place.
operation.
completely stopped.
slippage.
WARNING
Pendant linstallation et o lentretien des filtres, une courroie
en mouvement ou un ventilateur en opration peuvent causer
des blessures graves o mme causer la mort.
Deflection =
Belt span
64
Belt span
Small sheave
diameter (in)
0.0 to 3.5
A, AX
B, BX
5V, 5VX
McQuay IM 777
3+
min
max
min
max
min
max
3.0
5.0
2.5
4.0
2.0
3.5
3.6 to 4.4
3.5
5.0
3.0
4.5
2.0
4.0
4.5 +
4.0
5.5
3.0
5.0
2.5
4.5
0.0 to 5.4
5.5
8.0
4.5
7.0
3.5
5.5
5.5 to 7.6
5.5
8.5
4.5
7.5
3.5
5.5
7.7 +
6.5
9.0
5.0
8.0
4.0
6.5
0.0 to 8.5
7.0
11.0
5.5
9.0
4.0
7.0
8.6 TO 12.0
8.5
13.0
6.5
10.5
5.0
8.0
12.1 +
10.0
15.0
7.5
11.5
5.5
9.0
27
45%
65%
85%
95%
625
500
500
500
1.0
1.0
.50.70
1.0
65%
85%
95%
Efficiency
500
500
500
.43
.61
.70
1.5
1.5
1.5
70%
500
.39
1.2
F ilte r
F ra m e
R o ta te
W ir e C lip s
Perfect pleat
Efficiency
30%
30%
500
625
.36
.36
1.0
1.0
5700 filters
Filter Gauges
Efficiency
N/A
500
.25
Table 21 shows the typical filter pressure drop for clean filters
at rated air flow. The tables also show a final pressure drop for
front loaded filters.
1.0
Efficiency
2"
4"
70%
70%
.42
.37
1.0
1.0
Coils
1 The coil must be clean to obtain maximum performance.
overflow.
McQuay IM 777
5 After the fan sled is out, loosen the fan bearings and pull
WARNING
Mold can cause personal injury. Clean drain pan regularly so
mold does not develop.
AVERTISSEMENT
La moisissure prsente un danger respiratoire. Pour viter
la moisissure, nettoyer rgulirement le bassin de drainage.
AVERTISSEMENT
Avant denlever toute composante, couper et indiquer que
lalimentation lectrique lunit est coupe. Les
ventilateurs et les courroies peuvent entraner des blessures
personelles graves ou mme la mort.
and pull the entire assembly out the side of the unit.
out the shaft.
6 Disconnect the fan housing from the fan sled, and
connections.
7 Slip the panel over the connections.
8 Replace the brass plugs and panel fasteners.
McQuay IM 777
29
Connection
end
Coil
3 Remove the bolts holding the coil in place and then lift
holding it in place and then lift and slide the coil out.
Installing Stacked Coils
1 Slide the bottom coil through the opening in the coil
Connection end
Coil
Coil
1 Disconnect all piping and remove the brass plugs for the
Coil
Bulkhead
corners of the coil side plates. Remove the bolts and then
lift and pull the coil out the side.
4 The bottom coil is fastened to the air block off plate.
30
McQuay IM 777
Parts
Parts
Replacement Parts
When writing to McQuay for service or replacement parts,
refer to the model number and serial number of the unit
stamped on the serial plate attached to the unit. If replacement
parts are required, mention the date of installation of the unit
and date of failure, along with an explanation of the
malfunctions and a description of the replacement parts
required.
McQuay IM 777
31
Warranty
Consult your local McQuay Representative for warranty
details. Refer to Form 933-43285Y. To find your local
McQuay Representative, go to www.mcquay.com.
32
McQuay IM 777
To comply with the terms of McQuay Warranty, complete and return this form within 10
days to McQuay Warranty Department.
Check, test, and start procedure for McQuay Air Handling Units with or without heat recovery.
Job Name:________________________________________ McQuay S.O. No.: _________________ McQuay G.O. No.: _________________
Installation address: __________________________________________________________________________________________________
City: ______________________________________________________________________________ State: __________________________
Purchasing contractor:________________________________________________________________________________________________
City: ______________________________________________________________________________ State: __________________________
Name of Person doing start-up (print) ___________________________________________________________________________________
Company name _____________________________________________________________________________________
Address ___________________________________________________________________________________________
City/State/Zip_______________________________________________________________________________________
Unit model number: ________________________________________________ Unit serial number: _______________________________
SF VFD model number:_____________________________
RF VFD model number:_____________________________
N/A
N/A
Circle Yes or No. If not applicable to the type of unit, circle N/A.
I. INITIAL CHECK
A. Is any shipping damage visible? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
D. Have the hold-down bolts been backed off on spring mounted fan isolators? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Volts __________
Hertz __________
Phase __________
12 _________ V
23__________V
13 _________ V
L1____________
L2 ___________
L3 ___________
12 _________ V
23__________V
13 _________ V
L1____________
L2 ___________
L3 ___________
_________Hertz
_________Phase
B. Are there any signs of physical damage to the electric heat coils? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
L12_________V
L23 ________ V
L13 _______ V
Stage 3
Stage 4
Stage 5
____________
____________
McQuay IM 777
___________
Stage 2
___________
___________
Stage 6
___________
33
___________
___________
____________
____________
___________
___________
Phase L3
___________
___________
____________
____________
___________
___________
G. FLA:
L1 ___________
L2 ___________
L3____________
H. Operate electric heat with fans off. Electric heat must cycle OFF on high limit control. . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Signature: ______________________________________________________
N/A
Startup date:____________________________________
34
McQuay IM 777
State: __________________
State: __________________
Yes
No
N/A
Good
Fair
Poor
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Workmanship
Design
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Good
Fair
Poor
Good
Fair
Poor
Fair
Poor
10. How would you rate the overall quality of the product?
Excellent
11. How does the quality of McQuay products rank in relation to competitive products?
Excellent
Good
Comments:
Please list any additional comments which could affect the operation of this unit; i.e., shipping damage, failed
components, adverse installation applications, etc. If additional comment space is needed, write the comment(s) on a
separate sheet, attach the sheet to this completed Quality Assurance Survey Report, and return it to the Warranty
Department with the completed preceding Equipment Warranty Registration Form.
McQuay IM 777
35
Now that you have made an investment in modern, efficient McQuay equipment, its care should be a high priority.
For training information on all McQuay HVAC products, please visit us at www.mcquay.com and click on training,
or call 540-248-9646 and ask for the Training Department.
Warranty
All McQuay equipment is sold pursuant to its standard terms and conditions of sale, including Limited Product
Warranty. Consult your local McQuay Representative for warranty details. Refer to Form 933-43285Y. To find your
local McQuay Representative, go to www.mcquay.com.
This document contains the most current product information as of this printing. For the most up-to-date product
information, please go to www.mcquay.com.
05/10
TAB 4
Installation Manual
SD-IOM-1.0
6-15-02
Duct Connections
2" TYP
Optional
Hanger Bracket
70738001
1 1/2" TYP
1 1/2" TYP
2" TYP
W / ATTENUATOR
1 1/2" TYP
2" TYP
W / ELECTRIC HEAT
1 1/2" TYP
Figure 1. Single Duct Recommended Hanger Bracket Locations
SD-IOM-2.0
Field Wiring
All field wiring must comply with the local codes and
with the National Electrical Code (ANSI/NFPA 70-1981).
Electrical, control and piping diagrams are shown on the
exterior labeling or on the diagram on the inside of
control enclosure cover. All electric heaters if provided
by TITUS are balanced by kW per stage. The installing
electrician should rotate these heater stages by phase
in order to help balance the building electric load.
6-15-02
Replacement Parts
Description
Part Number
31171301
31171302
31171303
31171304
31171305
31171306
31171307
31171308
70300301
70300302
70300303
70324901
Control Tube
Red Stripe 1/4" O.D.
Green Stripe 1/4" O.D.
Red Stripe 3/8" O.D.
Green Stripe 3/8" O.D.
Yellow Stripe 1/4" O.D.
White Stripe 1/4" O.D.
Blue Stripe 1/4" O.D.
61510035
61510234
61510279
61510280
61510260
61510261
61510262
Calibration Instructions
42150011
42150020
42160081
10015601
TAB 5
PN 471558
Downblast Centrifugal Roof Exhaust Fans
Model G
Direct Drive
Model G is a direct drive downblast
centrifugal exhaust fan. These fans
are specifically designed for roof
mounted applications exhausting
relatively clean air. Performance
capabilities range up to 4,300 cfm
(7,305 m3/hr) and up to 1in.wg
(249Pa) of static pressure. The
maximum continuous operating
temperature is 180F (82C).
Gmodels are available in sixteen
sizes with nominal wheel diameter
ranging from 8 to 18 inches
(203to457 mm) (060-180unitsizes). Each fan shall bear
a permanently affixed manufacturers engraved metal
nameplate containing the model number and individual
serial number. All fans are UL/cUL listed Standard 705.
Model GB
Belt Drive
GB Model Fans are belt drive
downblast centrifugal exhaust
fans. These fans are specifically
designed
for
roof
mounted
applications exhausting relatively
clean air. Performance capabilities
range up to 44,700 cfm (75,950
m3/hr) and up to 2.5in.wg (623 Pa)
of static pressure. The maximum
continuous operating temperature
is 180F (82C). GBmodels are
available in twenty sizes with
nominal wheel diameters ranging
from 11 to 54 inches (279 to 1372 mm) (071-540 unit sizes).
Each fan shall bear a permanently affixed manufacturers
nameplate containing the model number and individual
serial number. All fans are UL/cUL listed Standard 705.
DANGER
Always disconnect, lock and tag power source before
installing or servicing. Failure to disconnect power
source can result in fire, shock or serious injury.
CAUTION
When servicing the fan, motor may be hot enough
to cause pain or injury. Allow motor to cool before
servicing.
CAUTION
Receiving
Upon receiving the product check to make sure all items
are accounted for by referencing the bill of lading to
ensure all items were received. Inspect each crate for
shipping damage before accepting delivery. Notify the
carrier if any damage is noticed. The carrier will make
notification on the delivery receipt acknowledging any
damage to the product. All damage should be noted on
all the copies of the bill of lading which is countersigned
by the delivering carrier. A Carrier Inspection Report
should be filled out by the carrier upon arrival and
reported to the Traffic Department. If damaged upon
arrival, file a claim with carrier. Any physical damage
to the unit after acceptance is not the responsibility of
Greenheck Fan Corporation.
Hook With
Safety Latch
(Supplied by others)
(2) Bearing Plate
Lifting Points
Fig. 2
Screws
Screws
Unpacking
Verify that all required parts and the correct quantity
of each item have been received. If any items are
missing, report shortages to your local representative to
arrange for obtaining missing parts. Sometimes it is not
possible that all items for the unit be shipped together
due to availability of transportation and truck space.
Confirmation of shipment(s) must be limited to only items
on the bill of lading.
Handling
G Direct Drive
Lift unit on to the roof utilizing hooks under the lip of the
shroud. Evenly space the hooks around the shroud using
a minimum of four lifting straps. Use a spreader bar to
ensure the straps do not come in contact with the unit
(see figure 1).
Fig. 3
1 in.
(44 mm)
Curb Cap
Storage
Spreader Bar
Lifting
Strap
Indoor
Fig. 1
Hook
GB Belt Drive
When lifting the unit on to the roof, use either the four
lifting points on the drive frame or the two lifting points
on the bearing plate if present (see figure 2 for lifting
points). Access to the drive frame is accomplished by
removing the screws pointed out in figure 3. The cover
can then be removed and placed on a flat surface in an
area protected from strong winds.
Outdoor
Fans designed for outdoor applications may be stored
outdoors, if absolutely necessary. Roads or aisles for
portable cranes and hauling equipment are needed.
The fan should be placed on a level surface to prevent
water from leaking into the fan. The fan should be
elevated on an adequate number of wooden blocks so
that it is above water and snow levels and has enough
blocking to prevent it from settling into soft ground.
Locate parts far enough apart to permit air circulation,
sunlight and space for periodic inspection. To minimize
water accumulation, place all fan parts on blocking
supports so that rain water will run off.
Do not cover parts with plastic film or tarps as these
cause condensation of moisture from the air passing
through heating and cooling cycles.
Fan wheels should be blocked to prevent spinning
caused by strong winds.
MOTOR
SUPPLY VOLTAGE
115/208-230/60/1
J-BOX
Fig. 4
SUPPLY VOLTAGE
208-230/460/60/3
J-BOX
L1
L2
L1
L3
L2
Installation
WARNING
Installation, troubleshooting and parts replacement
is to be performed only by qualified personnel.
WARNING
Disconnect power before installing or servicing.
G - Direct Drive
G Direct Drive
Damper
Roof
Opening
*Approx.
Weight
8 (203)
1012 (267)
18 (8)
10 (254)
12 2 (318)
26 (12)
G 101, 121
19 (483)
12 (305)
14 2 (368)
43 (20)
G 131,141
22 (559)
16 (406)
18 2 (470)
58 (26)
G 150
26 (660)
16 (406)
18 2 (470)
59 (27)
G 160, 170
30 (762)
18 (457)
20 2 (521)
81 (37)
G 180
30 (762)
18 (457)
20 2 (521)
118 (54)
Model
Curb
Cap
Curb
Cap
Damper
Roof
Opening
*Approx.
Weight
19 (483)
12 (305)
14 (368)
58 (26)
GB 101, 101HP
19 (483)
12 (305)
14 (368)
63 (29)
GB 121
19 (483)
12 (305)
14 (368)
66 (30)
GB 131
19 (483)
12 (305)
14 (368)
67 (30)
GB 141, 141HP
22 (559)
16 (406)
18 (470)
83 (38)
GB 161, 161HP
22 (559)
16 (406)
18 (470)
89 (40)
GB 180, 180HP
30 (762)
18 (457)
20 (521)
125 (57)
GB 200, 200HP
30 (762)
18 (457)
20 (521)
138 (63)
34 (864)
24 (610)
26 (673)
158 (72)
GB 260
40 (1016) 30 (762)
32 (826)
305 (138)
GB 300, 300HP
40 (1016) 30 (762)
32 (826)
320 (145)
GB 330
46 (1168) 36 (914)
38 (978)
385 (175)
GB 360, 360HP
46 (1168) 36 (914)
38 (978)
403 (183)
GB 420
52 (1321) 42 (1067)
44 (1130)
495 (225)
GB 480
52 (1321) 48 (1219)
50 (1283)
623 (283)
GB 500
64 (1626) 54 (1372)
56 (1435)
687 (312)
GB 540
64 (1626) 54 (1372)
56 (1435)
748 (339)
Disconnect
Screws
in.
Wiring by Others
GB - Belt Drive
Model
8 or 12 in.
(203 or 305)
(19)
Damper
1 in.
(32)
Recommended Duct
and Damper Size
Recommended Roof
Opening
1 in.
(32)
*Dimensions shown
in inches (mm)
GB Belt Drive
Fig. 6 - Typical Roof Mounting Installation
Disconnect
in
Wiring by Others
8 or 12 in
(203 or 305)
(19)
Damper
1 in
(32)
*Dimensions shown
in inches (mm)
Recommended Duct
and Damper Size
1 in
(32)
Recommended Roof
Opening
Pre-Starting Checks
1. Check all fasteners and set screws for tightness. The
wheel should rotate freely and be aligned as shown
in figure 7 on page 5.
2. Wheel position is preset and the unit is test run at the
factory. Movement may occur during shipment and
realignment may be necessary.
3. Only G unit - Centering height alignment can be
accomplished by loosening the set screws in the
wheel and moving the wheel to the desired position.
4. Only GB unit - Centering can be accomplished by
loosening the bolts holding the drive frame to the
shock mounts and repositioning the drive frame.
5. Only GB unit - Wheel and inlet cone overlap can be
adjusted by loosening the set screws in the wheel
and moving the wheel to the desired position.
G 060-095
G 101-180
GB 071-161
4 (6)
4 (6)
8 (10)
2 (13)
GB 180-240
GB 260-540
Belts
Fig. 9
.
10. If adjustments are made, it is very important
to check
the pulleys for proper alignment. Misaligned pulleys
lead to excessive belt wear vibration, noise and
power loss, see figure 10.
Fig. 7
Wheel Rotation
Fig. 10
Counterclockwise
Airflow
Fasteners
(4) *Fasteners
Fig. 8
Counterclockwise
Airflow
G 141-180
Clockwise
Airflow
G 060-131
All GB Models
Fig. 11
Clockwise
Airflow
WARNING
WARNING
The fan has been checked for mechanical noises at the
factory prior to shipment. If mechanical noise should
develop, suggested corrective actions are offered in
the Troubleshooting section.
IMPORTANT
Over tightening will cause excessive bearing wear and
noise. Too little tension will cause slippage at startup
and uneven wear.
Model GB
Pre-Starting Belt Tension Checks
8. Always loosen tension enough to install belts without
stretching, see figure 9.
9. For units with two groove pulleys, adjust so the
tension is equal in both belts.
*Identical fasteners on
opposing side must also be
loosened.
Deflection
Slack
Side
Fig. 12a
Fig. 12b
Operation: G / GB
1. Before starting up or operating fan, check all
fasteners for tightness. In particular, check the
setscrews in wheel hub.
2. While in the OFF position or before connecting the
fan to power, turn the fan wheel by hand to be sure it
is not striking the venturi or any obstacle.
3. Start the fan and shut it off immediately to check
rotation of the wheel with directional arrow in the
motor compartment.
4. When the fan is started, observe the operation and
check for any unusual noises.
5. With the system in full operation and all ductwork
attached, measure current input to the motor and
compare with the nameplate rating to determine if
the motor is operating under safe load conditions.
6. Keep inlets and approaches to fan clean and free
from obstruction.
IMPORTANT
Adjust (tighten) belt tension after the first 24-48hours
of operation.
Inspection
Inspection of the fan should be conducted at the first
30minute and 24 hour intervals of satisfactory operation.
30 Minute Interval
Inspect bolts, setscrews and motor mounting bolts.
Adjust and tighten as necessary.
24 Hour Interval
Check all internal components. On GB unit only, inspect
belt alignment and tension. Adjust and tighten as
necessary.
Maintenance: G / GB
Installation and maintenance are to be performed only
by qualified personnel who are familiar with local codes
and regulations and who are experienced with this type
of equipment.
Motor maintenance is generally limited to cleaning and
lubrication (where applicable). Cleaning should be limited
to exterior surfaces only. Removing dust buildup on
motor housing ensures proper motor cooling.
WARNING
Always disconnect, lock and tag power source before
servicing. Failure to disconnect power source can
result in fire, shock or serious injury.
CAUTION
Uneven cleaning of the wheel will produce an out of
balance condition that will cause vibration in the fan.
WARNING
This unit should be made non-functional when cleaning
the wheel or housing (fuses removed, disconnect
locked off).
Mobil 532
Premium BRB #2
Texaco, Inc.
Texaco Multifak #2
Rykon Premium #2
Exxon
Unirex N2
Shell
B Shell Alvania #2
Type of Service
1 to 3
3 to 6
6 to 12
12 to 18
Poor
Poor
Good
In order to assure proper fan performance, caution must be exercised in fan placement and connection to the
ventilation system. Obstructions, transitions, poorly designed elbows, improperly selected dampers, etc, can cause
reduced performance, excessive noise and increased mechanical stress. For performance to be as published, the
system must provide uniform and stable airflow into the fan.
Good
Poor
Poor
Good
Provide uniform
airflow at fan inlet
to assure optimum
performance.
Troubleshooting
WARNING: Before taking any corrective action, make certain unit is not capable of operation during repairs.
PROBLEM
EXCESSIVE NOISE /
VIBRATION
HIGH HORSEPOWER
MOTOR OVERLOADS /
OVERHEATS
REDUCED AIRFLOW
CAUSE
CORRECTIVE ACTION
Adjust wheel and/or inlet cone. Tighten wheel hub or bearing collars
on shaft.
V-belt drive
Bearings
Wheel unbalance
Clean all dirt off wheel. Check wheel balance, rebalance in place if
necessary.
Bad bearings
Replace.
Secure properly.
Fan
Duct system
Electrical supply
Drive
Motor
Lubrication
Mechanical
Belt slippage
Undersized motor
Check motor ratings with catalog speed and air capacity chart.
Clean wheel.
Dampers closed
Clean or replace.
Belt slippage
Speed to slow
Maintenance Documentation
Job Information
Job Name:
Service Organization:
Address:
Address:
City:
City:
State:
Zip:
State:
Zip:
Phone:
Phone:
Contact Person:
Nameplate Information
Model:
Actual Voltage:
Volts:
Hertz:
Phase:
Actual Phase:
Amps:
Mark:
Actual Amperage:
Supply hp:
Exhaust hp:
Blower Rotation:
Serial Number:
Hertz:
Air Volume:
Model Voltage:
Design cfm:
Actual cfm:
Motor Amperage:
Fan RPM:
(max.)
Maintenance Log
Date
Time
Notes
Parts List
NOTE
Each fan bears a manufacturers nameplate with model number and serial number embossed. This information will assist
the local Greenheck representative and the factory in providing service and replacement parts. Before taking any corrective
action, make certain unit is not capable of operation during repairs.
CAUTION
A fan manufactured with an explosion resistant motor does not certify the entire unit to be explosion proof.
Motor Cover
Motor
Shock Mounts
Shroud
Birdguard
Wheel
Curb Cap/Venturi
Hood Clip
Shroud Brace
Vertical Support
Lower Windband
Motor Cover
Belt
Shaft Pulley
Motor Pulley
Drive Frame
Assembly
Bearings
Shock Mounts
Motor
Fan Shaft
Shroud
Wheel
Conduit Chase
Birdguard
Shroud Brace
Windband
Vertical Support
Curb Cap/Venturi
Warranty
Greenheck warrants this equipment to be free from defects in material and workmanship for a period of three years
from the purchase date. Any units or parts which prove defective during the warranty period will be replaced at our
option when returned to our factory, transportation prepaid. Motors are warranted by the motor manufacturer for a
period of one year. Should motors furnished by Greenheck prove defective during this period, they should be returned
to the nearest authorized motor service station. Greenheck will not be responsible for any removal or installation costs.
As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications
without notice.
Greenheck Catalog G/GB provides additional information
describing the equipment, fan performance, available accessories,
and specification data.
AMCA Publication 410-96, Safety Practices for Users and Installers of
Industrial and Commercial Fans, provides additional safety information.
This publication can be obtained from AMCA International, Inc. at:
www.amca.org.
Contact Greenheck Fan Corporation:
Phone: (715) 359-6171 Fax: (715) 355-2399 E-mail: gfcinfo@greenheck.com Website: www.greenheck.com
Part #459968
Tubular Centrifugal & Mixed Flow
Model TCF
Tubular Centrifugal Inline Fan
Receiving
Upon receiving the product check to make sure all
items are accounted for by referencing the bill of
lading to ensure all items were received. Inspect
each crate for shipping damage before accepting
delivery. Notify the carrier if any damage is noticed.
The carrier will make notification on the delivery
receipt acknowledging any damage to the product.
All damage should be noted on all the copies of the
bill of lading which is countersigned by the delivering
carrier. A Carrier Inspection Report should be filled out
by the carrier upon arrival and the Traffic Department.
If damaged upon arrival, file claim with carrier. Any
physical damage to the unit after acceptance is not
the responsibility of Greenheck Fan Corporation.
Unpacking
Verify that all required parts and the correct quantity
of each item have been received. If any items are
missing report shortages to your local representative
to arrange for obtaining missing parts. Sometimes it
is not possible that all items for the unit be shipped
together due to availability of transportation and truck
space. Confirmation of shipment(s) must be limited to
only items on the bill of lading.
Handling
Fans are to be rigged and moved by the lifting
brackets provided or by the skid when a forklift is
used. Location of brackets varies by model and size.
Handle in such a manner as to keep from scratching
or chipping the coating. Damaged finish may reduce
the ability of the fan to resist corrosion.
Fans should never be lifted by the shaft, fan housing,
motor, belt guard, windband or accessories.
Storage
Fans are protected against damage during shipment.
If the unit cannot be installed and operated
immediately, precautions need to be taken to prevent
deterioration of the unit during storage. The user
assumes responsibility of the fan and accessories
while in storage. The manufacturer will not be
responsible for damage during storage. The following
suggestions are provided solely as a convenience to
the user.
INDOOR
The ideal environment for the storage of fans and
accessories is indoors, above grade, in a low humidity
atmosphere which is sealed to prevent the entry of
blowing dust, rain, or snow. Temperatures should
be evenly maintained between 30F (-1C) and
110F (43C) (wide temperature swings may cause
condensation and sweating of metal parts). All
accessories must be stored indoors in a clean, dry
atmosphere.
OUTDOOR
Roads or aisles for portable cranes and hauling
equipment are needed.
The fan should be placed on a level surface to prevent
water from leaking into the fan. The fan should be
elevated on an adequate number of wooden blocks so
that it is above water and snow levels and has enough
blocking to prevent it from settling into soft ground.
Locate parts far enough apart to permit air circulation,
sunlight, and space for periodic inspection. To
minimize water accumulation, place all fan parts on
blocking supports so that rain water will run off.
The use of a tarp to cover the unit will aid in keeping it
clean and dry. Avoid using a black plastic tarp as it will
promote condensation.
Fan wheels should be blocked to prevent spinning
caused by strong winds.
QEI/QEID Alignment
Straight Edge
Wheel
Cone
1 Fan
Wheel
Dia.
TCF Overlap
Overlap is adjusted by
loosening the wheel hub from
the shaft and moving the
wheel to the desired position
along the shaft. The chart
shows the proper distance
between the wheel and
Radial
the inlet cone.
Gap
TCF Size
18
20
22
24
27
30
33
36
40
44
49
54
60
66
73
Dimension A (in.)
6 8
7
71316
858
9716
10916
11716
1234
14316
15916
1718
181316
201516
2278
2512
3
8
1316
1316
14
14
38
38
38
38
38
12
12
12
12
12
1
Poor
Radial
Gap
Inlet Cone
Installation
Length of
Installations with poor inlet or discharge
Straight Duct
configurations may result in reduced fan performance.
Ducted Installations
Inlet Duct Turns Installation of a duct turn or elbow
too close to the fan inlet reduces fan performance.
Restricted or unstable flow at the fan Good
inlet can cause
pre-rotation of incoming air or uneven loading of the
fan wheel, yielding large system losses and increased
sound levels. To achieve full fan performance, there
should be at least one fan wheel diameter between
the turn or elbow and the fan inlet.
Good
Poor
1 Fan
Wheel
Dia.
Turning
Vanes
Dimension A (mm)
86
178
198
219
240
268
291
324
360
395
435
478
532
581
648
3
5
5
6
6
10
10
10
1 Fan
Wheel
Dia.
10
10
13
13
13
13
13
Discharge Duct
Turns Fan performance
is reduced
Poor
Good
Poor
when duct turns are made immediately
off the fan
discharge. To achieve cataloged fan performance
there should be at least three equivalent duct
1 straight
Fan
diameters ofWheel
ductwork between the fan
Dia.
Poor
discharge and any duct turns.
Poor
Length of
Straight Duct
Good
Length of
Straight Duct
Good
Models TCF and Model QEI/QEID Centrifugal
Non-Ducted Installation
1 Fan
Wheel
Unit Start-Up
Poor
DANGER
High voltage electrical input is needed for this
equipment. This work should be performed by a
qualified electrician.
Length of
Straight Duct
WARNING
Duct Connections
It is highly recommended to use a flexible sleeve
connection instead of a rigid duct connection. This will
reduce vibration transmission through the ductwork.
Slip-Fit End Connection (QEI/QEID)
Directly attach the flexible sleeve to the duct and fan.
1 Fan
No additional parts are required.
Wheel
Dia.
Flexible Sleeve
Flexible Sleeve
Fan
Duct
Turning
Vanes
Fan
Duct
1 Fan
Wheel
Dia.
Good
Fan
Duct
Fan
Duct
1. Disconnect
and lock-out all power switches to
Good
fan.
2. Check all fasteners, set screws and locking
collars on the fan, wheel, bearings, drive, motor
base and accessories for tightness.
Good
3. Rotate
the fan wheel by hand and assure no parts
are rubbing.
4. Check for bearing alignment and lubrication.
5. Check the V-belt drive for proper alignment and
tension.
6. Check all guarding (if supplied) to ensure that it is
securely attached and not interfering with rotating
parts.
7. Check operation of variable inlet vanes or
discharge dampers (if supplied) for freedom of
movement.
8. Check all electrical connections for proper
attachment.
Poor
9. Check housing and ductwork, if accessible,
for obstructions and foreign material that may
damage the fan wheel.
10. Check for proper wheel rotation by momentarily
energizing
the fan. Rotation should correspond
Poor
to the rotation decal affixed to the unit (CCW
rotation is correct as viewed from the fan inlet).
Companion Flange
Companion Flange
Centrifugal Airfoil
Vibration
Excessive vibration is the most frequent problem
experienced during initial start-up. Left unchecked,
excessive vibration can cause a multitude of
problems, including structural and/or component
failure.
The most common sources of vibration are:
Wheel unbalance
Drive pulley misalignment
Incorrect belt tension
Bearing misalignment
Mechanical looseness
Faulty belts
Drive component unbalance
Poor inlet/outlet conditions
Foundation stiffness
Many of these conditions can be discovered by careful
observation. Refer to the Troubleshooting section
of this manual for corrective actions. If observation
cannot locate the source of vibration, a qualified
technician using vibration analysis equipment should
be consulted. If the problem is wheel unbalance,
inplace balancing can be done providing there is
access to the fan wheel. Any correction weights
added to the wheel should be welded to either the
wheel back (single-plane balance) or to the wheel
back and wheel cone (two-plane balance).
Maintenance
WARNING
Disconnect and secure to the Off position all
electrical power to the fan prior to inspection
or servicing. Failure to comply with this safety
precaution could result in serious injury or death.
Once the unit has been put into operation, a routine
maintenance schedule should be set up to accomplish
the following:
1. Lubrication of bearings and motor.
2. Variable inlet vanes should be checked for freedom
of operation and wear.
3. Wheel, housing, bolts and set screws on the entire
fan should be checked for tightness.
V-Belt Drives
V-belt drives must be checked on a regular basis
for wear, tension, alignment and dirt accumulation.
Premature or frequent belt failures can be caused by
improper belt tension (either too loose or too tight)
or misaligned sheaves. Abnormally high belt tension
or drive misalignment will cause excessive bearing
loads and may result in failure of the fan and/or motor
bearings. Conversely, loose belts will cause squealing
on start-up, excessive belt flutter, slippage and
overheated sheaves. Either excessively loose or tight
belts may cause fan vibration.
When replacing V-belts on multiple groove drives,
all belts should be changed to provide uniform drive
loading. Do not pry belts on or off the sheave. Loosen
belt tension until belts can be removed by simply
lifting the belts off the sheaves. After replacing belts,
ensure that slack in each belt is on the same side of
the drive. Belt dressing should never be used.
Do not install new belts on worn sheaves. If the
sheaves have grooves worn in them, they must be
replaced before new belts are installed.
The proper tension for operating a V-belt drive is
the lowest tension at which the belts will not slip at
peak load conditions. Belts are adjusted by raising or
lowering the motor pivot plate. For initial tensioning,
the proper belt deflection half-way between sheave
centers is 1/64 of the belt span. For example, if the
belt span is 64 inches, the belt deflection should be
1 inch using moderate thumb pressure at mid-point
of the drive. Check belt tension two times during
the first 24 hours of operation and periodically
thereafter.
Deflection = Belt Span
64
Belt Span
V-Belt Replacement
MOTOR
FAN
Motors
Motor maintenance is generally limited to cleaning
and lubrication. Cleaning should be limited to exterior
surfaces only. Removing dust and grease build-up on
the motor housing assists proper motor cooling.
CAUTION
Do not allow water or solvents to enter the motor or
bearings. Under no circumstances should motors or
bearings be sprayed with steam, water or solvents.
Greasing of motor bearings is only required when
fittings are provided. Many fractional motors are
permanently lubricated and require no further
lubrication. Motors supplied with grease fittings
should be greased in accordance with the
manufacturers recommendations. When motor
temperature does not exceed 104F (40C), the grease
should be replaced after 2000 hours of running time.
MOTOR
Bearing Bore
15
2 - 1 1 8 - 1 2 1 8 - 178 -12316
16
2716
-3
3316
- 312
31516
- 412
To 250
500
750
1000
1250
0.5
0.5
1500
0.5
0.5
0.25
2000
0.5
0.25
0.25
0.25
2500
0.5
0.5
0.25
0.25
0.25
3000
0.5
0.25
0.25
0.25
WARNING
Lubricate bearings prior to periods of extended
shutdowns or storage and rotate shaft monthly to
aid in preventing corrosion. If the fan is stored more
than three months, the bearings should be purged
with new grease prior to start-up.
Model TCF
Model QEI
Housing
Inlet
Cone
Wheel
Shaft/Bearing
Assembly
Cover
Plate
Inlet
Cone
Shaft/Bearing/
Bearing Plate Assembly
Wheel
Housing
Troubleshooting
Problem
Cause
Corrective Action
Adjust wheel and/or inlet cone. Tighten wheel hub or bearing collars
on shaft.
V-Belt Drive
Bearings
Wheel Unbalance
Clean all dirt off wheel. Check wheel balance, rebalance in-place if
necessary.
Fan
Duct System
Fan
Duct System
Fan
Duct System
Electrical Supply
Drive
Motor
Lubrication
Mechanical
Belts
System Unbalance
Excessive Noise
Bearings Overheated
Excessive Vibration
Warranty
Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from
the purchase date. Any units or parts which prove defective during the warranty period will be replaced at our option
when returned to our factory, transportation prepaid. Motors are warranted by the motor manufacturer for a period of
one year. Should motors furnished by Greenheck prove defective during this period, they should be returned to the
nearest authorized motor service station. Greenheck will not be responsible for any removal or installation costs.
As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications
without notice.
Phone: (715) 359-6171 Fax: (715) 355-2399 E-mail: gfcinfo@greenheck.com Website: www.greenheck.com
PN 473681
Vari-Green Motor
Installation, Operation and Maintenance Manual
Please read and save these instructions for future reference. Read carefully before attempting to assemble,
install, operate or maintain the product described. Protect yourself and others by observing all safety
information. Failure to comply with instructions could result in personal injury and/or property damage!
Vari-Green Motor
The Vari-Green Motor is an electrically
commutated (EC) motor that uses 115V
single phase input power and internally
converts it to a DC power supply which
provides an 80% turndown capability
and increased energy savings.
DANGER
Always disconnect, lock and tag power source before
installing or servicing. Failure to disconnect power
source can result in fire, shock or serious injury.
CAUTION
When servicing the fan, motor may be hot enough
to cause pain or injury. Allow motor to cool before
servicing.
CAUTION
Precaution should be taken in explosive
atmospheres.
Vari-Green Motor
Installation
1. Install motor in accordance with local codes. Verify
fasteners holding motor to fan are properly secured
and wheel is properly secured on motor shaft.
Operation
The Vari-Green motor offers 3 different control options.
Follow the correct wiring diagram based on the control
option desired.
NOTES
2 VDC IS 15% AND 10 VDC IS 100%
OF NAMEPLATE RPM.
0-1.9 VDC IS OFF.
Vari-Green Motor
The two settings are: 0-10V and 2-10V. The fan will
operate on either one of these settings.
Wiring
Verify that any power connected to the fan is
disconnected before making the control connections.
When the remote speed control option is ordered,
a 4x4 junction box containing a transformer will be
included in the motor compartment of the fan (on the
housing of an inline fan).
This wiring diagram is located on the junction box
cover for convenience.
Using 3-wire control cable, make the following
connections:
Transformer Box
Speed Controller
Yellow
Blue
Red
Vari-Green Motor
Remote Mounted
Speed Controlled Motor
Troubleshooting
If the motor RPM does not vary in accordance with
the dial input, perform a voltage check to ensure the
motor is receiving the correct control input.
At the speed controller:
Terminals
Desired Voltage
1-2
24VAC Nominal
1-3
0-10VDC
(varies with dial position)
Maintenance
The Vari-Green motor utilizes brushless technology
with sealed bearings so no maintenance is required
other than keeping any accumulated debris from
collecting on the motor.
Features
Soft Start
All motors are a soft start motor. They will reliably
start at any speed setting.
Overload Protection
If the motor ever becomes overloaded, it will slow
itself down to the point where it is no longer being
overloaded. This means that the motor will never
burn itself out due to running into the service
factor as is a concern with many AC motors.
Locked Rotor Protection
If the motor ever sees a locked rotor condition, the
motor will automatically shut itself down. It will then
try to restart itself up to 3 times. If after the 3rd time
it still will not rotate, the motor will not attempt to
restart until after power is cycled.
Thermal Protection
The motor has a one-shot fuse thermal protector.
This is meant to protect the motor from a severe
temperature rise. With the motor softwares ability
to limit the motor if overloaded, the fuse is used as
a last resort to prevent a fire.
Warranty
Greenheck warrants this equipment to be free from defects in material and workmanship for a period of
one year from the purchase date. Any units or parts which prove defective during the warranty period will
be replaced at our option when returned to our factory, transportation prepaid. Motors are warranted by the
motor manufacturer for a period of one year. Should motors furnished by Greenheck prove defective during
this period, they should be returned to the nearest authorized motor service station. Greenheck will not be
responsible for any removal or installation costs.
As a result of our commitment to continuous improvement, Greenheck reserves the right to change
specifications without notice.
Greenheck Catalog provides additional information describing
the equipment, fan performance, available accessories, and
specification data.
Phone: (715) 359-6171 Fax: (715) 355-2399 E-mail: gfcinfo@greenheck.com Website: www.greenheck.com
4
TAB 6
Part #463384
VCD Models
Vertical and Horizontal Mount
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Receiving and Handling
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Safety WARNING:
)lacipyT( "2/1 1
Due to continuing research, Greenheck reserves the right to change specifications without notice.
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desreveR elgniS
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Pre-Installation Guidelines
The basic intent of a proper installation is to secure the volume control damper into the opening in such a manner as to
prevent distortion and disruption of damper operation. The following items will aid in completing the damper installation in a
timely and effective manner.
1) Check the schedules for proper damper locations within the building. Visually inspect
the damper for damage.
2) Lift or handle damper using sleeve or frame. Do not lift damper using blades, linkage,
actuators, or jackshafting. When handling multiple sections assemblies, use sufficient
support to evenly lift at each section mullion (see drawing). Do not drag, step on, apply
excessive bending, twisting, or racking.
Spreader Bar
Attachments
3) Do not install screws in damper frame that will interfere with unexposed blade linkage
and prevent damper blades from opening and/or closing.
4) Damper must be installed into duct or opening square and free of twist or other
misalignment. Damper must not be squeezed or stretched into duct or opening. Out of
square, racked, twisted or misaligned installations can cause excessive leakage and/or
torque requirements to exceed damper/actuator design.
5) Damper and actuator must be kept clean, dry and protected from dirt, dust and other foreign materials prior to and after
installation. Examples of such foreign materials include but are not limited to:
a)
b)
c)
d)
e)
Mortar dust
Drywall dust
Firesafing materials
Wall texture
Paint overspray
6) Damper should be sufficiently covered as to prevent overspray if wall texturing or spray painting will be performed
within 5 feet (1.50m) of the damper. Excessive dirt or foreign material deposits on damper can cause excessive leakage
and/or torque requirements to exceed damper/actuator design.
7) ACCESS: Suitable access (actuators maintenance, etc.) must be provided for damper inspection and servicing. Where it
is not possible to achieve sufficient size access, it will be necessary to install a removable section of duct.
Electrical Guidelines
Electrical and/or pneumatic connections to damper actuators should be made in accordance with wiring and piping
diagrams developed in compliance with applicable codes, ordinances and regulations.
safety CAUTION !
Verify power requirements before wiring
actuator. Greenheck is not responsible for
any damage to, or failure of the unit caused
by incorrect field wiring.
Installation -
safety DANGER !
Installation (continued)
14 ga.,
5 in. wide
Support
Mullion
Fig. 6
Fig. 8
Fig. 7
Fig. 9
2. If more than two sections wide, unit ships as a multiple section assembly and a single section together. The single
section is joined to the side of the multiple section where the jackshaft extends past the frame 4 inches.
3. D
uct opening or opening square should measure 1/4 inch (6mm) larger than damper dimension and should be straight
and level.
4. If no holes are present in frame, drill 1/4 inch (6mm) diameter holes at 6 inch (52mm) centers and fasten frames together
with 1/4 inch (6mm) #20 (.03mm) bolts and nuts.
5. U
se shims between damper frame and duct opening or opening space to prevent distortion of frame by fasteners
holding it in place. Brace at every horizontal mullion and vertically brace at every 8 feet (2.4m) of damper width for
strength. Dampers in high velocity (2000 fpm [610m per second]) may require more bracing. Note: Greenheck dampers
are specifically designed and engineered for structural integrity based on model and conditions. Attachment, framing,
mating flanges, and anchoring of damper assemblies into openings, ductwork, or walls is the responsibility of the
installer. Design calculations for these retaining and supporting members should be determined by field
engineers for that particular installation.
6. If
damper actuator is to be mounted out of the airstream, the extension pin should extend
approximately 6 inches (152mm) beyond the frame. On jackshafted units, the jackshaft should extend
through the jackshaft bearing assembly and approximately, 6 inches (152mm) beyond the frame.
7. Individual damper sections, as well as entire multiple section assemblies must be completely square and
free from racking, twisting, or bending. Measure diagonally from upper corners to opposite
lower corners of each section.
A
Do not twist
or bow. Mount
damper plumb
in the opening.
AF = BE
AB = CD
Installation (continued)
8. D
amper blades, axles, and linkage must operate without binding. Before system operation, cycle dampers after
installation to assure proper operation. On multiple section assemblies, all sections should open and close
simultaneously.
Damper Maintenance
Greenheck's dampers are designed to be trouble free and hassle free under normal operation. Dampers are to be installed
square and straight so as to prevent binding during operation. The following annual damper maintenance suggestions will
help to insure proper damper operation and increase the life expectancy of the damper.
Foreign Matter
Over the course of time, dirt and grime may collect on damper surfaces. The damper
surfaces should be cleaned to prevent hindrance to airflow.
Moving Parts
Make sure that parts such as linkage, bearings, blades, etc. that are intended to move
freely, can do so. Lubricating these components can prevent possible rusting and
unnecessary friction increase. Use only a moli-spray oil or similar graphite based oil as
regular lubricating oil will attract dirt.
Bearings. Synthetic, oil impregnated, and ball bearings (without grease fittings) do not
require lubrication. Ball bearings with grease fittings require only minimal grease.
Closure
Remove foreign materials that may be interfering with blade closure or effective sealing
of the blades with each other or with the frame.
Operation
While operating the damper through its full cycle, check to see that the blades open and
close properly. If there is a problem, check for loose linkage, especially at the actuator.
Tighten the linkage where required.
Possible Cause
Corrective Action
Defective motor
Replace
Contaminants on damper
Warranty
Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the
purchase date. Any units or parts which prove to be defective during the warranty period will be repaired or replaced at
our option. Greenheck shall not be liable for damages resulting from misapplication or misuse of its products. Greenheck
will not be responsible for any installation or removal costs. Greenheck will not be responsible for any service work or
backcharges without prior written authorization.
Copyright 2006 Greenheck Fan Corporation
#463384 VCD IOM Rev. 5 July 2006
TAB 7
3900 Dr. Greaves Rd.
(816) 761-7476
MAINTENANCE
Check actuator and tighten linkage if necessary.
Clean damper blades and other working parts if necessary.
Lubricate linkage, bearings and other moveable parts with a silicone lubricant. Do not use petroleum-based products as
they could cause excessive dust collection.
Operate (open and close) the damper via the actuator (see note).
Check the blades to make sure they completely close and re-open.
Consult Ruskin if problems are encountered.
MAINTENANCE
(refer to notes)
Check closure springs. If defective, repair or replace.
Operate the damper by removing the fusible link and allowing the blades to drop or close.
(Caution: keep fingers and hands out of the blade package travel path.)
Check the damper for rust and/or corrosion.
Clean damper blades and lubricate the working parts. Do not use petroleum-based products as they could cause excessive dust collection.
Re-open the damper (move the blade package back to the top of damper) and replace the fusible link.
TESTING DAMPERS
(refer to notes)
Use a heat source and melt the fuse link or remove the fuse link and let the blade package drop. (Caution: keep fingers and
hands out of the blade package travel path.)
Check the blades to make sure they completely close and lock (if a lock is used).
Notes:
1.Due to their construction (including size) and/or accessibility, dynamic curtain type fire dampers may be very difficult and in
some cases impossible to test (close and re-open). If the damper is determined to be impossible to test, Ruskin recommends a
thorough examination to insure nothing exists which would prohibit the damper from closing. A thorough examination should
include checking the damper for squareness and the blade channel for obstructions.
2.Fire dampers may be easier to reopen from a specific side. Consult Ruskin for assistance.
3.If possible, fire dampers should be tested under normal airflow conditions.
FSDOM-406/replaces FSDOM-803
Ruskin 2006
3900 Dr. Greaves Rd.
(816) 761-7476
SMOKE DETECTION/TEST/POWER
FAILURE OPERATION
If smoke is detected, or during testing, or if power failure occurs,
the damper will close and lock. When the smoke signal ceases (or
smoke detector resets) , the test is complete or power is restored
the SYSTEM will automatically REMOTE RESET the damper to
the open position. The damper automatically resets if nuisance
alarms occur and the SYSTEM is reset. The damper may be
closed at any time by placing the MCP1 (optional) or other control
switch (by others) in the CLOSED position.
FIRE OPERATION
When the switch of a control panel (MCP) is in the NORMAL position and temperatures in excess of 165F/74C (212F/100C
optional) are detected, the damper will close and lock and the
damper CLOSED indicator light on the control panel will light.
The damper remains closed until the override signal for smoke
management from a remote command station is present and the
duct temperature has not exceeded the high limit. The high limit
temperature sensor prevents the damper from reopening when
duct temperature is above the damper's UL555S degradation test
temperature of 250F/121C or 350F/177C. Upon cessation of
the fire condition, the damper can be reopened by pressing the
RESET button on the TS150 assembly. At no time will the damper
disengage from the actuator. The integral SP100 will positively
communicate to the fire commander via the control panel the position of the damper for smoke management purposes.
Refer to the appropriate damper installation instructions for details
on damper installation. All electrical wiring and connections to the
Fire-Stat must be in accordance with the standards of the authorities having jurisdiction.
SEE COMPLETE
MARKING
ON PRODUCT
ITEM
1. TS-150 Fire Stat
2. Adjustable Connecting
Rod
3. Flex Conduit
4. Damper Frame
5. Actuator or EP Switch
ITEM
6. Over-Center Lock
7. Damper Sleeve
8. FAST, PFMA or conventional mounting angles
9. Sleeve to Duct
Connection (by others)
S1 and S2 Switch AMP Ratings: 15 AMPS, @ 24, 125 or 250 VAC 1/2
AMP, @ 125 VDC, 1/4 AMP, @ 250 VDC
Blue
Yellow
Blue
Yellow
FS Primary
Heat Sensor
Manual
Reset
Brown
Orange
Brown
Black
HL High Limit
Temp. Sensor
Manual Reset
BY OTHERS
BLUE
II-TS150-1007/Replaces II-TS150-205
BLUE
Ruskin 2007
TAB 8
BRONZE
FITTED
P41780
P39020
P03470
P48690
P49373
H32600
PUMP CONSTRUCTION
BRONZE FITTED
ALL
WITH WEAR RING
IRON
*P44136
P41780
P48660
P39020
P39030
P03470
P03470
P48690
P48690
See Coupler Selection Table, Page 48
P49373
P49373
H32600
H32600
ALL
BRONZE
P41800
P39470
S04180
P48690
P49373
H32600
For ANSI/OSHA Coupling Guard & Bracket Kit Selection, See Chart on Page 49
P78523
P46380
186495
P61451
186862
186861
185011
P77103
185308
P75606
186002
186001
185140
P52350
J23874
P49369
H32500
J92558
J92291
P53550
186906
P78523
P46380
186495
P61451
186862
186861
185011
P77103
185308
P75606
186002
186001
185140
P52350
J23874
P49369
H32500
J92558
J92291
P53550
186906
P78253
P78523
P46381
P46390
186495
P56799
NONE
NONE
186860
186862
NONE
186861
185012
185013
P77103
P77103
+P78927 +P79018
P75606
P75606
186002
186002
186001
186001
185141
NONE
P52350
P52350
J23874
J23874
P49369
P49369
H32500 H32500
J92558
J92558
J92291
J92291
P53550
P53550
186906
186906
P78251
P51230
P51540
P51541
186543
185225
185014
P77161
P79027
P75612
186571
186572
185142
P13800
J23875
P49372
H32700
J92560
DJ0066
P53720
186905
186906
P78251
P51230
P51540
P51541
186543
185225
185014
P77161
P79027
P75612
186571
186572
185142
P13800
J23875
P49372
H32700
J92560
DJ0066
P53720
186905
186906
P78522
P46382
P51540
NONE
186544
NONE
185015
P77161
P79027
P75612
186571
186572
185143
P13800
J23875
P49372
H32700
J92560
DJ0066
P53720
186905
186906
P78251
P51250
P51560
NONE
186543
185225
185016
P77161
P79028
P75612
186571
186572
NONE
P13800
J23875
P49372
H32700
J92560
DJ0066
P53720
186905
186906
19
PARTS LIST
Standard
Design Pumps
SERIES 1510
CP-207F-PL
Size
Construction
Series
Serial No.
Date Manufactured
(October, 1988)
Flow
Head
HP
RPM
The nameplate identifies the pump in the example as a Series 1510, size 5G in bronze
fitted (BF) construction. A 123/4" impeller is beeing provided to meet 990 GPM at 150 ft.
at 1750 RPM. The serial number specifically identifies the unit for future reference. DO
NOT REMOVE THE NAMEPLATE. It is important when ordering replacement parts to
furnish complete nameplate data.
The 1510 pump is furnished with both Standard Seal or Stuffing Box configuration. The Standard Seal pump has no seal designation after the Series number on
the nameplate. If the example pump was of Stuffing Box configuration, the nameplate would show it to be a 1510-S, 1510-PF or 1510-D pump. Parts for Stuffing
Box type pumps are covered under the CP-206D-PL parts list.
To insure the correct parts are selected, use the following procedure:
1. Determine from the nameplate the pump size, seal configuration, pump construction and impeller diameter.
2. Measure shaft sleeve diameter at the seal.
3. Refer to the index for the page number of the parts breakdown for the specific size
pump.
4. Find the proper column in the parts breakdown for the pump construction involved.
5. Select part numbers, using the numbered drawings on page 4 for identification.
Where shaft diameter affects parts selection, use the measurement secured in
Step 2.
6. Bearing frames vary with motor frame sizes. Use the motor frame number (found
on the motor nameplate) to select the proper bearing frame from the chart on
page 5.
4
17
BEARING FRAME
COUPLER
SPRING
WASHER
18
26
10
IMPELLER
KEY
22
IMPELLER
CAPSCREW
20
BEARING
CAP
VOLUTE MOUNTING
CAPSCREW
P77375
P76922
BEARING LOCKWASHER
BEARING LOCKNUT
VOLUTE
IMPELLER CAPSCREW
IMPELLER WASHER
IMPELLER
IMPELLER
LOCKWASHER
SLINGER
SHAFT
SLEEVE
IMPELLER LOCKWASHER
IMPELLER KEY
13
SEAL KIT
BEARING CAP
21
VOLUTE GASKET
BALL BEARING
PUMP END
25
VOLUTE CAPSCREW
SHAFT
19
BALL BEARING
COUPLER END 14
COUPLER
KEY
SUPPORT FOOT
COUPLER KEY
GREASE FITTING
COUPLER END
- Factory recommended
spare parts.
MOTOR
SERIES 1510
Standard Seal Design Pump
Exploded View
1 /2"AC
2"AC
21/2"AB
3"AC
4"AC
5"A
11/4"BC
11/2"BC
2"BC
21/2"BB
3"BC
4"BC
5"BC
6"BC
2"E
3"E
4"E
5"E
6"E
2"G
3"G
4"GB
5"G
6"G
X
X
X
X
X
X
X
XX
X
X
XX
X
XX
XX
X
XX
X
X
X
X
X
X
X
X
X
XX
X
X
XX
X
X
X
X
X
X
X
X
X
XX
XX
XX
X
X
X
X
X
X
X
X
X
X
XX
XX
XX
XX
X
X
X
X
X
X
X
X
XX
XX
XX
XX
X
X
X
X
X
X
XX
XX
XX
254T
X
X
X
XX
XX
XX
213T
X
X
X
X
X
X
XX
XX
XX
XX
XX
254T
X
X
X
X
X
X
X
X
X
X
X
XX
XX
XX
XX
XX
XX
XX
256T
X
X
X
X
X
X
X
X
X
X
XX
XX
XX
XX
XX
XX
XX
XX
XX
X
X
X
X
X
X
X
X
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
X
X
X
X
X
X
XX
XX
XX
XX
XX
XX
XX
XX
X
X
X
XX
XX
XX
XX
XX
XX
XX
XX
XX
X
X
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
X
X
X
XX
XX
XX
XX
XX
215T
11/4"AC
56
Frame #
SIZE
31
OIL WICK
34
30
SLEEVE BEARING
REAR
14
COUPLER KEY
9
10
13
IMPELLER KEY
WATER
SLINGER
IMPELLER
LOCKWASHER
7
IMPELLER
CAPSCREW
BEARING
FRAME
ITEM
NO.
2
27
30
29
34
28
7
9
10
14
33
32
31
13
33
OIL CUP
DESCRIPTION
Bearing Frame Assembly
Consisting of:
Bearing Frame
Shaft & Sleeve
Sleeve Bearing (Front)
Sleeve Bearing (Rear)
Sleeve Bearing Gasket (Included with Bearings)
Impeller Capscrew
Impeller Lockwasher
Impeller Key (Straight) Aug. 1989 (H98) & After
Impeller Key (Woodruff) July 1989 (G98) & Before
Coupler Key (Straight) Aug. 1989 (G98) & After
Coupler Key (Woodruff) July 1989 (G98) & Before
Oil Cup
Oil Well Cover Before June 1965 (EE)
Oil Well Cover After June 1965 (FE)
Oil Wick Set (2 Sets Required)
Water Slinger
PART
NO.
186660
P11450
186628
186659
186658
P11390
P52350
J23874
P49369
H32500
P49373
H32600
P14010
N/A
P14051
118395
P53550
47
FOR PUMPS
WITH LARGE
BEARING FRAME
11/4" SHAFT
AT COUPLER
FOR
5G
AND
6G PUMPS
WITH EXTRA LARGE
BEARING FRAME
17/8 SHAFT
AT COUPLER**
FRAME SIZE
56
143T-145T
182T-184T
213T
215T
254T
256T
213T
215T
254T
256T
284T
284T
286T
286T
284TS
286TS
324T
326T
324TS
326TS
SHAFT
SPACE
11/4"
13/4"
13/4"
21/2"
21/2"
21/2"
21/2"
33/4"
33/4"
33/4"
33/4"
33/4"
4"*
33/4"
4"*
33/4"
33/4"
4"
4"
33/4"
33/4"
H.P.
/2-3/4
1
1 1 /2 2 3
2 3 5 71/2
5 71/2 10
71/2 10 15
15 20
20 25
71/2
10
15
20
25
25
30
30
30
40
40
50
50
60
MOTOR
SHAFT
SIZE
5
/8"
7
/8"
11/8"
13/8"
13/8"
15/8"
15/8"
13/8"
13/8"
15/8"
15/8"
17/8"
17/8"
17/8"
17/8"
15/8"
15/8"
21/8"
21/8"
17/8"
17/8"
364T
365T
404TS
326T
4"*
4"*
4"*
53/8"
60
75
100
50
23/8"
23/8"
21/8"
21/8"
364TS
53/8"
60
17/8"
365TS
53/8"
75
17/8"
404TS
53/8"
100
21/8"
405TS
53/8"
125
21/8"
48
COUPLER
186868
186869
186870
186871
186871
186873
P63240
186872
186872
P63239
186874
P63242
P63243
P63244
P63244
P63239
186874
P63245
P63247
P63242
P63244
P63248
P63250
P63253
P82096
P82097
P82096
2 REQD
P82158
2 REQD
P82158
P82141
P82161
P82162
SLEEVE FOR
WOODS
COUPLER
P78804(4J)
P78804(4J)
P78729(5J)
P78791(6J)
P78791(6J)
P78792(7S)
P78794(8S)
P78791(6J)
P78791(6J)
P78792(7S)
P78794(8S)
P78794(8S)
P78794(8S)
P78796(9S)
P78796(9S)
P78792(7S)
P78794(8S)
P78796(9S)
P78798(10S)
P78794(8S)
P78796(9S)
SPIDER FOR
LOVEJOY
COUPLER
P45540
P45540
P45540
P45532
P45532
P45532
P45532
P45532
P45532
P45532
P45532
P45532
P78798(10S)
P78802(11S)
P78802(11S)
P82098
P82098
P82142
P82142
P82144
INSTRUCTION MANUAL
P81673
REVISION F
DESCRIPTION
PUMP APPLICATION
OPERATION LIMITS
Unless special provisions have been made for your pump by
Bell & Gossett, the operational limits for Series 1510 Pumps
are as follows:
Maximum Working Pressure
Listed on pump nameplate.
SEAL OPERATING LIMITS
Standard Seals
BUNA-PH Limitations 7-9; Temperature Range -40 to +225F
EPTH-PH Limitations 7-11; Temperature Range -40 to + 250F
For use on closed or open systems which are relatively free of
dirt and/or other abrasive particles.
Flushed Single Seals
PH Limitations 7-9; Temperature Range 0 to +250F
NOTE: On closed or open low pressure systems that contain
a high concentration of abrasives an external flush is required.
SAFETY
INSTRUCTIONS
WARNING
This safety alert symbol will be used in this manual and on the
pump Safety Instruction decal to draw attention to safety related
instructions. When used, the safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN
A SAFETY HAZARD.
ROTATING COMPONENTS
FIGURE 3
(2) Required
(1 each side)
CAUTION
DO NOT RUN PUMP DRY,
SEAL DAMAGE MAY OCCUR.
INSPECT PUMP SEAL
REGULARLY FOR LEAKS,
REPLACE AS REQUIRED.
FOR LUBRICATION
REQUIREMENTS, CONSULT
SERVICE INSTRUCTIONS.
FAILURE TO FOLLOW
INSTRUCTIONS COULD
RESULT IN INJURY OR
PROPERTY DAMAGE.
P70644
Alternate
location
CAUTION
COUPLER ALIGNMENT IS
REQUIRED! LEVEL AND GROUT
PUMP BEFORE USE!
CHECK ALIGNMENT BEFORE
GROUTING, AFTER SYSTEM IS
FILLED, AFTER SERVICING
PUMP, AND AS REQUIRED.
CONSULT THE SERVICE
INSTRUCTIONS FOR DETAILS.
FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD
RESULT IN INJURY OR
PROPERTY DAMAGE.
P70820
WARNING
EYEBOLTS OR LIFTING
LUGS IF PROVIDED ARE
FOR LIFTING ONLY THE
COMPONENTS TO WHICH
THEY ARE ATTACHED.
FAILURE TO FOLLOW
INSTRUCTIONS COULD
RESULT IN INJURY
OR DEATH.
P70643
MECHANICAL SAFETY:
WARNING: Unexpected Startup Hazard
Disconnect and lockout power before servicing.
Failure to follow these instructions could result in serious
personal injury or death, or property damage.
WARNING: Excessive System Pressure Hazard
The maximum working pressure of the pump is listed
on the nameplate, do not exceed this pressure. Failure to
follow these instructions could result in serious personal
injury or death, or property damage.
WARNING: Excessive Pressure Hazard
Volumetric Expansion
The heating of water and other fluids causes volumetric
expansion. The associated forces may cause failure of system components and release of high temperature fluids.
This will be prevented by installing properly sized and
located compression tanks and pressure relief valves.
Failure to follow these instructions could result in serious
personal injury or death, or property damage.
PUMP LOCATION
Locate the pump so there is sufficient room for inspection,
maintenance and service. If the use of a hoist or tackle is
needed, allow ample head room.
FIGURE 4
IMPORTANT
Do not install and operate Bell & Gossett Pumps, 3D Valves,
Suction Diffusers, etc., in closed systems unless the system is
constructed with properly sized safety devices and control
devices. Such devices include the use of properly sized and
located pressure relief valves, compression tanks, pressure
controls, temperature controls, and flow controls as appropriate. If the system does not include these devices, consult
the responsible engineer or architect before making pumps
operational.
FIGURE 5
COLD WATER
SUPPLY
B&G ROLAIRTROL
AIR SEPARATOR
SUPPLY TO
SYSTEM
FROM BOILER
CHILLER OR CONVERTER
TYPICAL
PUMP
INSTALLATION
ISOLATION
VALVE
B&G
B&G
TRIP
LE
CIR
CU
DU
TY
IT S
ETT
ER
VAL
V
B&G SERIES
1510 PUMP
B&G SUCTION DIFFUSER
INSTALLATION
FOUNDATION BOLT
PIPE SLEEVE
This pump is built to provide years of service if installed properly and attached to a suitable foundation. A base of concrete
weighing 21/2 times the weight of the pump is recommended.
(Check the shipping ticket for pump weight.)
If possible, tie the concrete pad in with the finished floor. Use
foundation bolts and larger pipe-sleeves to give room for final
bolt location. (See Figure 6A.)
WASHER
FIGURE 6A
INSTALLATION OF
FOUNDATION BOLTS
BUILT-UP
CONCRETE FOUNDATION
FIGURE 6B
GROUT
.
APPROX
1" GAP
LEVELING
Place the pump on its concrete foundation supporting it with
steel wedges or shims totaling 1" in thickness. These wedges
or shims should be put on both sides of each anchor-bolt to
provide a means of leveling the base. (See Figure 6B.)
CONCRETE FOUNDATION
GROUTING
After the pump has been leveled, securely bolted to the floor,
and properly aligned, a good grade of non-shrinking grout
should be poured inside the pump base. To hold wedges or
shims in place, allow the grout to flow around them. (See
Figure 6B).
ROTATION
Pump rotation is clockwise when viewed from back of the
motor. An arrow is also located on the pump to show the
direction of rotation.
COUPLER ALIGNMENT
All alignment should be done by moving or shimming the
motor only. Adjustments in one direction may alter alignment
in another. Therefore, check alignment in all directions after a
correction is made. Black rubber sleeves have different
horsepower load ratings then orange Hytrel sleeves, they
should not be interchanged.
STRAIGHT EDGE
FIGURE 7A
Before aligning the coupler, make sure there is at least 1/8" end
clearance between the sleeve and the two coupler halves.
1. Check angular misalignment using a micrometer or caliper.
Measure from the outside face of one flange to the outside
face of the opposite flange at four points 90 apart. Refer to
figure 7B. DO NOT ROTATE COUPLER. Misalignment up to
1
/64" per inch of coupler radius is permissible.
2. At four points 90 apart (DO NOT ROTATE COUPLER),
measure the parallel coupler misalignment by laying a
straight edge across one coupler half and measuring the
gap between the straight edge and opposite coupler half.
Up to a 1/64" gap is permissible. Refer to figure 7A.
DISTANCES ACROSS
COUPLER FLANGES
SHOULD BE EQUAL
(CHECK 4 PLACES)
ANGULAR ALIGNMENT CHECK
FIGURE 7B
PIPING
PIPING
NOTES:
1. The pipeline should have isolation valves around the pump
and have a drain valve in the suction pipe.
2. When installing the suction and discharge connections to a
threaded pump housing the use of teflon tape sealer or a
high quality thread sealant is recommended.
PUMP INSULATION
When insulating a Series 1510 pump, ensure that the bearing
assembly grease fittings remain accessible and visible. The
vent slots on the sides and bottom of the bearing assembly
should remain uncovered and completely open.
LUBRICATION
GENERAL INSTRUCTIONS
INNER GUARD
OUTER GUARD
NUT
LOCKWASHER
CAPSCREW
FLAT WASHER
SUPPORT BRACKET
SPACER WASHER
MOTOR SADDLE BRACKET
ATTACH TO MOTOR SADDLE
FIGURE 9
VOLUTE
IMPELLER
VOLUTE GASKET
COVERPLATE
BEARING FRAME
SEAL ASSEMBLY
SHAFT
SLINGER
BEARING FRAME
CAPSCREWS
SHAFT SLEEVE
SUPPORT FOOT
IMPELLER KEY
SUPPORT FOOT CAPSCREWS
IMPELLER
WASHER
IMPELLER CAPSCREW
DRAIN PLUG
FIGURE 10
BEARING
FRAME
COVERPLATE
VOLUTE
GASKET
VOLUTE
IMPELLER
FLUSHING
TUBE
LANTERN
RING
PACKING
PACKING
GLAND
SHAFT
SLINGER
SHAFT
SLEEVE
BRACKET
IMPELLER
KEY
IMPELLER
W
ASHER
VOLUTE
CAPSCREWS
IMPELLER
CAPSCREW
DRAIN PLUG
IMPELLER
LOCK
WASHER
FIGURE 12
1510-D
FIGURE 11
1510-S
MOTOR END
MOTOR END
O-RING
COVERPLATE
FOR 11/4" SEAL
113/32"
O-RING
SEAL CAP
O-RING
SERVICE INSTRUCTIONS
WARNING: UNEXPECTED STARTUP HAZARD
Disconnect and lock out power before servicing.
Failure to follow these instructions could result in serious personal injury or death, or property damage.
4. Remove support foot capscrews. Loosen volute capscrews, do not remove them. Use capscrews in the jack
screw holes (Not on 8G). Loosen the pump assembly from
the volute.
10. Slide a new rotating seal assembly onto the shaft sleeve.
With a screwdriver push on the top of the compression
ring until the seal is tight against the seal insert. Install seal
spring, with narrow end toward seal.
11. Install impeller, impeller washer, lock washer and capscrew. Tighten capscrew per torque chart (See Table 1).
12. Install new volute gasket then install pump assembly into
volute. Tighten volute capscrews per torque chart (See
Table 1). Install seal flushing tube, if used. Install support
foot capscrews and tighten per torque chart (See Table 1).
Install coupler and align. Install drain plug, close drain
valve.
13. Install the Hex Coupler Guard as follows:
a. Spread the inner guard and place it over the coupler.
NOTE: Do not spread the inner and outer guards more
than necessary for guard installation. Over spreading
the guards may alter their fit and appearance.
b. With the inner guard straddling the support bracket,
install a cap screw through the hole in the support
bracket and guard located closest to the pump. Do not
tighten the capscrew.
c. Spread the outer guard and place it over the inner
guard.
d. Install the outer guard cap screws by following the step
stated below which pertains to your particular pump:
I) For pumps with a motor saddle support bracket:
Ensure the outer guard is straddling the support arm,
and install but do not tighten the two remaining cap
screws.
II) For pumps without a motor saddle support bracket:
Insert the spacer washer between the holes located
closest to the motor in the outer guard, and install
but do not tighten the two remaining cap screws.
e. Position the outer guard so it is centered around the
shaft, and so there is less than a 1/4" of shaft exposed.
f. Holding the guard in this position, tighten the three cap
screws.
14. Open isolation valves, inspect pump for leaks, if not leaking return pump to service.
1510-S Stuffing Box
With Special Single Mechanical Seal Figure 10 and 11
1510-8G
With Standard Mechanical Seal Figure 13
5. Remove the impeller nut and washer. Remove the impeller
and impeller key.
6. Remove spacer sleeve and two nuts holding the gland to
the stuffing box.
7. Pull the coverplate off the bearing frame assembly. Remove
the seal, sleeve and gland.
8. Thoroughly clean the shaft, shaft sleeve and the coverplate
seal cavity. Inspect for surface damage like pitting, corrosion, nicks or scratches.
9. Apply Dow Corning Silicone Rubber #732 or equal to the
shaft at sleeve location. Slide the shaft sleeve onto the
shaft and spin sleeve to distribute sealant. Wipe off excess.
10. Slide the seal gland (flat side towards the stuffing box) on
the shaft.
6. Remove hex nuts from seal cap bolts and remove coverplate capscrews. Remove coverplate from bracket.
12. Install the seal spring and spring retainer onto the shaft
sleeve. Slide the coverplate onto the bearing frame.
13. Install spacer sleeve (over the shaft sleeve), impeller key,
impeller, washer and impeller nut, then tighten impeller nut
to 25-30 ft-lbs. Install and tighten the gland nuts evenly
against the stuffing box.
9
FIGURE 13
IMPELLER KEY
SPACER SLEEVE
SHAFT SLEEVE
FLUSH TUBE
GLAND
WEARING RING
VOLUTE
SHAFT
IMPELLER NUT
BEARING FRAME
SLINGER
IMPELLER
MECHANICAL SEAL
DRAIN PLUG
COVERPLATE
O-RING
10
OPTIONAL
CASING
WEAR RINGS
Head
Marking
Capscrew Diameter
1/4
5/16
3/8
7/16
1/2
5/8
10
16
24
46
17
30
50
76
48
Stainless Steel
SAE Grade 5
DEALER SERVICING
If trouble occurs that cannot be rectified contact your local
representative. He will need the following information in order
to give you assistance.
1. Complete nameplate data of pump and motor.
2. Suction and discharge pipe pressure gauge readings.
3. Ampere draw of the motor.
4. A sketch of the pump hook-up and piping.
11
TUV
CERT
DIN ISO 9001
ISO 9001
Certified
USA
Bell & Gossett
8200 N. Austin Avenue
Morton Grove, IL 60053
Phone: (847) 966-3700
Facsimile: (847) 966-9052
http://www.bellgossett.com
INTL.
Bell & Gossett / Export Dept.
8200 N. Austin Avenue
Morton Grove, IL 60053
Phone: (847) 966-3700
Facsimile: (847) 966-8366
Cable: BELGOSSETT
CANADA
Fluid Products Canada
55 Royal Road
Guelph, Ontario,
N1H 1T1, Canada
Phone: (519) 821-1900