FanMaster™ Energy Saving Package Installation Manual (v2.xx) Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http:// www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited. Throughout this manual, when necessary we use notes to make you aware of safety considerations. WARNING: Identifies information about practices or circumstances ! that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. Important: Identifies information that is critical for successful application and understanding of the product. ATTENTION: Identifies information about practices or circumstances ! that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequences. Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present. Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures. Rockwell Automation, Allen-Bradley, PanelView, PanelView Component, PowerFlex and MicroLogix are trademarks or registered trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual Table of Contents Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Preface General Information Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1 What is Contained in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1 Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1 Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2 Chapter 1 FanMaster Overview FanMaster Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 FanMaster Externally Mounted Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 FanMaster Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 FanMaster Application Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Integration of FanMaster into Building Automation Systems . . . . . . . . . . . . . . . . . . . . 1-12 Chapter 2 FanMaster Installation General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Chapter 3 FanMaster Configuration and Start Up Using the PanelView C600 HMI Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Gather and Record Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Configure the FanMaster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 View Detailed Data Log Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Start or Stop Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Clear the Data Logs and Collect Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Chapter 4 Troubleshooting FanMaster Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 FanMaster Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Appendix A Specifications and City Climate Profiles Drives and FanMaster Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 City Climate Profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Appendix B FanMaster Diagrams Drawing Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Appendix C FanMaster Screens and Field Descriptions Dashboard Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Air Handler Unit Diagram Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 Setup Screen #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 Setup Date and Time Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5 Setup Screen #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6 Setup Screen #3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7 Supply Fan Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8 Return Fan Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9 Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329 2 Fan Communication Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10 Cooling and Heating Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10 Proof of Flow Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12 Data Collection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13 User City Weather Data Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14 Data Log #1 Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15 Data Log #2 Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16 Data Log #3 Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17 System Status Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-18 Appendix D FanMaster Application Firmware Upgrades Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 Upgrade the FanMaster MicroLogix 1100 Controller Application Firmware . . . . . . . . . D-1 Upgrade the FanMaster PanelView Application Firmware. . . . . . . . . . . . . . . . . . . . . . . . D-3 Restart FanMaster with the New Application Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . D-8 Index Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329 Preface General Information Who Should Use This Use this manual if you are responsible for installing and/or operating the Manual Allen-Bradley® FanMaster™ Energy Saving Package (FanMaster). You must have a thorough understanding of installation and operation of HVAC units, Building Automation Systems (BAS) and electrical circuitry and components in order to successfully install this product. What is Contained in this This manual provides installation and configuration information for the Manual FanMaster product only. Refer to Reference Materialson pagep-2 for information on associated products. Before you begin the installation and configuration of FanMaster, it is recommended that you read Chapter 1 - FanMaster Overview. To install and configure FanMaster, complete the instructions in each of the following chapters, sequentially: – Chapter 2 - FanMaster Installation – Chapter 3 - FanMaster Configuration and Start Up Manual Conventions The following words are used throughout the manual to describe an action: Word Meaning Can Possible, able to do something Cannot Not possible, not able to do something May Permitted, allowed Must Unavoidable, you must do this Shall Required and necessary Should Recommended Should Not Not recommended Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329 p-2 General Information Reference Materials Rockwell Automation publications are available on the internet at www.rockwellautomation.com/literature. The following manuals are recommended for additional information: Title Publication No. PowerFlex 400 AC Drive Packages for Fan & Pump Applications Installation 22C-IN002 Manual PowerFlex 400 Adjustable Frequency AC Drive for Fan & Pump Applications User 22C-UM001 Manual PowerFlex 70 Adjustable Frequency AC Drive Installation Instructions 20A-IN009 PowerFlex 70 AC Drives User Manual 20A-UM001 PowerFlex 700 Adjustable Frequency AC Drive Frames 0…6 Installation 20B-IN019 Instructions PowerFlex 700 AC Drives Series B Vector Control User Manual 20B-UM002 PowerFlex 750-Series AC Drive Installation Instructions 750-IN001 PowerFlex 750-Series AC Drives User Manual 750-UM001 20-COMM-H RS-485 HVAC Adapter User Manual 20COMM-UM009 Wiring and Grounding Guidelines for PWM AC Drives DRIVES-IN001 PanelView Component HMI Terminals User Manual 2711C-UM001 MicroLogix 1100 Programmable Controllers User Manual 1763-UM001 For Allen-Bradley Drives Technical Support: Title Online at . . . Allen-Bradley Drives Technical Support www.ab.com/support/abdrives Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329 1 Chapter FanMaster Overview FanMaster Description FanMaster provides a means for improving the energy efficiency of Constant Air Volume HVAC units. Constant Air Volume HVAC units typically draw in room air and mix it with a small amount of outside air. This mixed air is forced by a fan through heating and/or cooling elements to provide supply air back to the room at a temperature that makes up for heating or cooling lost to the surrounding environment. This maintains comfortable conditions for the building’s occupants and contents. FanMaster improves the efficiency of a basic HVAC unit by providing the following two additional control features: (cid:129) FanMaster replaces a fixed speed fan motor starter with a Variable Speed AC Drive which allows the fan speed to adjust to the actual HVAC heating and cooling loads. The Law of Affinity states that the energy required to operate a fan decreases by the cube of the actual speed reduction. For example, a fan running at 80% of its maximum speed requires about 50% of the energy needed to run the fan at full speed. And, a fan running at 50% of its maximum speed requires only about 13% of the energy needed to run the fan at full speed. FanMaster’s ability to monitor the HVAC operation and adjust the fan speed to the required value provides considerable opportunity for savings. (cid:129) FanMaster regulates the amount of outside air drawn into the HVAC unit for the purpose of ventilation by monitoring the actual Carbon Dioxide (CO ) level in the serviced space. This feature, known as Demand 2 Ventilation, maintains air quality while reducing the cost of heating or cooling the outside air by reducing its volume. The typical Constant Air Volume HVAC unit selected by the building's original designer provides adequate heating, cooling, and ventilation for worst-case conditions. The heating and cooling capacity are selected for the coldest and hottest days anticipated and the ventilation capacity is designed for maximum human occupancy. Since the weather is seldom at the extremes in most locations and buildings are often occupied at less than full capacity, FanMaster provides a savings opportunity by reducing the fan speed and ventilation used by the HVAC unit when they are not required. In addition, when the weather extremes do require maximum heating or cooling or the CO level indicates the need for maximum ventilation, 2 FanMaster returns the fan to its original full speed and ventilation to the original designed value until conditions are such that it can once again reduce the fan speed and amount of outside air ventilation. FanMaster has been designed for installation into an existing HVAC system with minimal interface with the existing controls. FanMaster does not replace or interfere with the existing controls which continue to regulate room temperature. In addition, FanMaster can also be installed and used in an evaluation only mode (without a fan drive). This mode allows the FanMaster energy savings calculator to provide an estimate of potential savings, prior to performing a full installation. Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329 1-2 FanMaster Overview FanMaster Externally Temperature Sensors Mounted Components Two temperature sensing probes are provided with FanMaster. These probes are essential to FanMaster because the measured difference in temperature between these sensors provides the command signal for the fan speed. The temperature sensors are typically mounted on the outside of the Constant Air Volume HVAC unit, with the sensing probe penetrating into the air flow inside through a hole drilled into the side of the HVAC enclosure. The placement of the Mixed Air sensor should be selected after examining the interior of the HVAC unit to ensure that the probe is located in a position that will accurately measure the temperature of the combined outside and return air before entering the heating and cooling section. Avoid a location that is in the upper, lower or edge portion of the air stream and one which may be unduly influenced by the air entering the unit from the outside air damper. If the Mixed Air temperature probe does not accurately reflect the average temperature entering the heating and cooling elements, the fan speed will not be set properly. The supply air sensor should be mounted from 6 inches to 5 feet downstream of the final heating or cooling element. Because the temperature of the air can be warmer at the top of the air stream and cooler at the bottom, the probe should be mounted as close to the vertical center of the air flow as possible. Carbon Dioxide Sensor The CO sensor (if installed) is usually mounted in the room return air flow 2 of the HVAC unit prior to mixing with outside air. Alternatively, the CO2 sensor can be mounted directly on the return air duct work serving a specific area that is most likely to be affected by high CO2 concentrations during occasions of high occupancy. This will ensure that FanMaster will allow full fan speed and normal ventilation when and where it is most needed. This is the most typical installation. Alternatively, the CO sensor can be mounted directly in the conditioned 2 space in an area that is most likely to be affected by high CO 2 concentrations during occasions of high occupancy. This will ensure that FanMaster will allow full fan speed and normal ventilation when it is most needed. It may be desirable to invest in individual CO room monitors for critical 2 locations. It has been found that certain buildings lack adequate ventilation prior to installation of FanMaster. If FanMaster seems to be running in CO 2 override even during periods of low occupancy, it is advised that you seek help from an HVAC air quality professional for advice on how to best rectify the ventilation problems. Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329 FanMaster Overview 1-3 Pressure Sensor (Optional) In certain applications it may be necessary or desirable to maintain a positive building pressure relative to the outside air. A pressure sensor can be ordered with FanMaster which monitors the differential pressure between the inside and outside air. When the differential pressure is lower than a user specified setpoint, the FanMaster will override to 100% fan speed to try to restore the desired minimum pressure differential. One typical scenario where pressure override might occur is when a loading dock door is opened to allow for a delivery, and additional airflow is required to restore the pressure differential when the door closes. The sensor requires connection to two lengths of 1/4 inch OD plastic tubing which sample the inside and outside air pressure at their respective termination points. You may need to experiment with the location of the tubing since normal wind and airflow often causes localized air pressure deviations around a building which may result in inaccurate pressure measurements. You may find that the HVAC unit fan speed has no measurable affect on building pressure. In this case turn off the pressure mode completely and do not use the sensor. When using a pressure sensor the Constant Ventilation mode described below is not available. Damper Position Indicator Switch Many existing HVAC systems have a feature known as “economizer mode” or “free cooling mode”. These systems monitor the outside air temperature and humidity and when conditions are such that the outside air can be used to provide cooling (instead of using the cooling element) the existing typical system will open the outside air damper fully to allow maximum use of this “free” cooling. FanMaster uses a Damper Position Indicator switch to indicate when the existing control system is in economizer mode. The switch is installed on the outside air damper in a location that causes its contacts to close when the damper opens beyond the normal 10% ventilation position. In order to take full advantage of economizer mode, FanMaster increases the speed of the fan to 100% until the existing control determines that economizer mode is no longer appropriate. The economizer control will then return the damper to its normal ventilation position and the contacts in the damper position indicator switch will open. This signal is sent to FanMaster, which allows the fan to return to its normal reduced speed and damper override functions. The switch must be installed in a position that will actuate when the damper opens. It may be mounted directly on the damper blades, on the damper actuator arms or linkage, or on the center axle of a damper blade section. Because there are many different damper systems in use, the installation may require fabrication of a custom linkage or mounting method if no suitable location is available. Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329 1-4 FanMaster Overview Fan Starter Current Sensor This device is used only when FanMaster is installed in evaluation mode. The current sensor device is designed such that one wire lead of the existing fan motor passes through its center. The current sensor has a switch that actuates when it senses current flow in the motor wire, indicating that the fan motor has been started by the existing control system. The actuated switch identifies when the HVAC unit fan normally runs so the FanMaster calculator can take into account the HVAC normal hours of operation and more accurately project monthly cumulative savings. Fan Starter Hard-Wired Interconnection This device is used only when FanMaster is installed with a drive. FanMaster requires a start signal from the existing BAS system in order to know when to start and stop the fan. The control signal on the coil of the existing fan motor starter provides this signal. The starter coil signal is typically 115V AC or 26V AC. Two interposing relays, one that accommodates each of these voltages, are shipped with FanMaster (120V AC relay already installed at position CR4). Other control voltage relays are available from Rockwell Automation. FanMaster Operation Fan Speed Reduction With the installation of FanMaster, the existing HVAC control system continues to maintain room temperature by monitoring its own temperature sensors and controlling the heating and cooling elements. FanMaster provides new, independent temperature sensors mounted in the airflow of the HVAC unit. These sensors allow FanMaster to determine if the existing controls are requesting heating and cooling and to adjust the fan speed to a value appropriate for the amount of heating and cooling required. As the existing controls call for more heating or cooling (as determined by the amplitude of the temperature differential measured before and after the heating and cooling elements), FanMaster responds by increasing the fan speed. As the amount of heating or cooling required decreases, the temperature differential decreases and so does the FanMaster fan speed. If the existing controls are not calling for heating or cooling, then there is no temperature differential across the heating and cooling elements and FanMaster reduces the fan speed to a user specified minimum speed. Reducing the HVAC unit’s fan speed when not calling for maximum heating or cooling results in significant savings in the energy required to run the fan, according to the Law of Affinity. Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329