Guide for Installation and Maintenance of MacroAir (ME Series) High Volume Low Speed Fans Version 9.0 April 2014 1
Delivery: Upon receipt of fans, thoroughly inspect units for any damage sustained during transit. If damaged, contact Pacific HVAC Engineering or your supplying distributor immediately. Site Storage: If the fan is not installed immediately, it should be stored in a clean, dry and preferably warm environment. Safety: Rotating fan impellers and electric motors can be dangerous to personnel; only experienced qualified persons should carry out work on these products. The following precautions must be taken: Electrically isolate the fan motor prior to undertaking any work. Check that all fasteners, particularly impeller fasteners, are tight prior to start up. Do not re-use locking fasteners. Electrical Supply: Check that suitable supply is available. 415V, Three Phase, 50Hz. Motor Electrical Information All electrical installation shall comply with AS/NZS 3000:2000. MacroAir fans use a 0.94kW Electronically Commutated Motor. There are no special requirements for wiring 3 phase power to the unit, and Neutral is not required. For control wiring use data cable when using the 1 fan controller and when using a MODBUS system use a MODBUS/PROFIBUS cable to add the fans to the network. Check the shipment against the list below and ensure that all components are available before beginning the installation. Fan Components 1) Fan Blade Box a. 6 x MACROAIR Blades 2) Mounting Hardware Kit a. 1 x Cover Plate b. 1 x Keyless Bush c. 1 x Pivot d. 2 x Clamp Plates e. 2 x Spacer Plates f. 6 x Safety Links g. 6 x Link Extensions h. 1 x 6mm Safety Cable i. 4 x 3mm Guy Wire Cables j. 1 x Mounting Hardware Bolt Kit k. 1 x Blade Bolt Kit l. 1 x Hub Assembly Bolt Kit m. 1 x Quick Start Guide 3) Power Unit Box a. 1 x Frame b. 1 x Gear Motor 4) Hybrid Hub Box a. 1 x Hybrid Hub 5) Fan Controller (Where Applicable) a. 1 x MacroAir Controller 6) Extension Tube (Where Applicable) 2
Guidelines for Positioning Fans Check the installation area to determine clearances around the fan. The optimal mounting height is 1.5 2 times the diameter of the fan (fans can be mounted up to 15m above ground level). Mounting Requirements 1) The blades of the fan must be at least 3m above floor level 2) The blades must be at least 0.6m away from vertical and horizontal features 3) The blades must be at least 1.5m away from the edge of a mezzanine floor if less than 3m above the floor level. 4) Roof / Ceiling clearance must greater than 15% of the fan diameter ( as an average if the roof is sloping part of the fan can be closer) 5) The fan must mounted between and preferably above lighting fixtures to prevent shadow strobing. 6) Smoke Detectors shall be mounted at least 1m outside the sweep of the fan blades 7) The hub of the fan shall be at least 1.5m from sprinkler heads, blades shall be at least 0.9m from sprinkler heads 8) Any local regulatory and legislative and insurance guidelines must be adhered to. 9) The fan must be attached to a primary building structure that is rated for the weight of the fan unit. Typically, I beams are the preferred support structure. Advice should be sought from Pacific HVAC Engineering or a suitably qualified structural engineer for installations to non primary structural elements. 3
Assemble the motor hub 1. Take the nuts from the safety plate, and then line up the bolts of the safety plate with the corresponding holes on the frame of the power unit. Reattach the nuts and tighten securely to 20N.m using 5/8 spanners or sockets. 2. Inset the first part of the keyless bush into the hole in the aluminium hub. 3. Push the keyless bush over the shaft of the gearmotor and into the centre hole on the hybrid hub, lining up the 4 holes in the keyless bush and the hub 4. Using the 4 gold coloured bolts and spring washers in the hub assembly bolt kit, tighten the keyless bush onto the shaft, tightening to 24Nm in a star pattern with a 7/16 socket and use a thread locking compound on the thread. Ensure that the ring plate on the hybrid hub is moving clear of the safety plate to ensure the operation of the fan is not impeded. 5. Screw the cover plate over the keyless bush and shaft assembly. 4
Install the Fan 1) Attach the pivot assembly to the roof structure. Mount the large plate of the pivot against the underside of the beam. Ensure that the long axis of the plate is at 90 o to the axis of the beam. Place the clamp plates on top of the beam flange and bolt them to the mount with 4 of M12 x 60 8.8Grade bolts and locknuts. For thicker I beams, use the supplied spacer plates between the pivot and the clamps. 2) Attach the optional extension Bolt the extension tube to the pivot using 4 of M12 x 40 8.8Grade Bolts and Locknuts 3) Attach the motor hub to the pivot or extension Attach the motor hub to the pivot or optional extension tube with 4 of M12 x 40 8.8Grade Bolts and Locknuts with the hybrid hub on the downward side. 4) Remove and discard black rubber transportation tube from gear box breather valve. 5) Attach the safety cable Loop the 6mm steel safety cable around the beam and through the frame of the power unit and clamp with the supplied cable clamps. The installation of the safety cable is mandatory, and no warranty will be issued for fans without the safety cable. 6) Complete the electrical installation of the fan motor. 5
7) Attach the guy wires Guy wires should be mounted at an angle of approx. 45 o in the vertical plane and at 90 o from each other. Place the turnbuckle ends of the cables on the loops provided on the power unit frame and make taut, ensuring that the fan frame remains vertical. The installation of the guy wires is mandatory and no warranty will be issued for fans without guy wires. 8) Attach the blades a. Ensure the blades are correctly orientated. They are an airfoil design, and the thick edge is the leading edge. The underside is the concave side. b. Slide the blade over the stub on the hybrid hub, aligning the channel in the blade with the stub. c. Put a bolt in the outer hole to locate the blade d. Place the safety links over the top side of the inner hole and put a bolt through the safety links and inner hole. The safety links and safety link extensions are mandatory and no warranty will be issued for fans without safety links and extensions. e. Place the safety link extension over the bolts protruding on the underside of the blade and bolt the blade assembly to the hub. f. Repeat for all blades and tighten all bolts (Note: do not tighten bolts until all blades are fitted). 6
9) Install Control Unit and Wire to Fan Motor WARNING: Ensure 415V power supply to the fan motor is disconnected before installing the control unit. The user Control Unit (On/Off Man/Auto Speed Control) should be installed remotely from the fan unit so as to provide easy access. Position the Control Unit within direct line of sight to the MacroAir fan. Ensure the controller is easily visible and located in a position protected from physical damage, direct sunlight and moisture. MacroAir fans can be controlled by an analogue 0-10V signal or via MODBUS. When operating as a MODBUS system use appropriate data cable and wire to the RSA/RSB terminals on each fan. When using the MacroAir controller, wire as per Fig.1 below with appropriate data cable. It is required that 6 terminals are to be wired to ground level to facilitate any future programming changes. Motor Control Junction Box Orange Blue Brown Red Black Yellow RSA RSB +10V 0-10V Analogue Input GND +20V +10V 0-10V Analogue Input GND +20V Y R B Macroair Controller MODBUS Control Optional Temperature Sensor Fig. 1 7
The following guidelines apply in setting up MacroAir to be controlled via an external MODBUS controller The motors used in the MacroAir fans are designed to accept MODBUS RTU over RS485 serial line. Default settings for MODBUS communication with MacroAir fans are a baud rate of 19,200 bit/sec, even parity configuration and 1 stop bit. Wiring shall be completed according to local standards, taking into account the details provided in the operating instructions. Figure 2 below is provided as reference for connecting the MacroAir fans into a MODBUS control system. Addressing the Fans Figure 2 Suggested wiring for MODBUS control system To have a fully functioning MODBUS system, each MODBUS device must have a unique address on the MODBUS system. You will be required to change the address of each MacroAir fan installed on site, as each fan will leave the factory with default address of 1. The address of the fan can be checked and changed using holding register D100. See section 2.9 of the MODBUS protocol supplied with the MacroAir for details of accepted values. 8
Setting up the Fans Since each size of MacroAir fan has its own specific operating details, there are a number of changes that will need to be made using connection through the external controller. Parameter Register (Register Type) Required Input Protocol Reference Section Source Set Value D101 (holding) RS485 2.10 Operating Mode D106 (holding) Closed Loop Speed Control 2.16 Maximal Speed D119 (holding) See Table 2 for maximum speed by fan diameter Ramp-up Curve D11F (holding) 90 seconds 2.28 2.26 Reset D000 (holding) Reset must be used to apply parameter changes and reset errors 2.2 Table 1 Initial Set-up Parameters Impeller Diameter Maximum Motor rpm Impeller Diameter Maximum Motor rpm Operation of the Fans 2.4m 8ft 1690 4.8m 16ft 1750 3m 10ft 1660 5.4 18ft 1750 3.6m 12ft 1400 6m 20ft 1475 4.2m 14ft 1200 7.2m 24ft 1230 Table 2 Maximum Speeds for MacroAir fans by Diameter Fan speed is determined by the value in the Default Set Value, holding register D001. This will only have effect provided Source Set Value (D101) has been changed to accept RS485. To start the fan, enter a value that is defined in part (a) of section 2.3 in the MODBUS protocol. The value entered will be a function of the required speed and the maximum speeds shown in Table 2. To stop the fan, a value of 0 should be entered into the register. Input register D011 (motor status) can be used to read errors that may be present in the system. See section 3.9 of the MODBUS protocol for a list of errors that can be found. Input register D012 (warning) can be used to read warnings that may be present in the system. See section 3.10 of the MODBUS protocol for a list of warnings that can be found. Input register D000 is used to reset errors and apply parameter changes. Inputting a value of 2 is required to apply parameter changes, but it will not reset failures. Inputting a value of 4 into this register resets failures only. Inputting a value of 6 into this register will both apply parameter changes and reset failures. 9
10) Commission the Installation WARNING: Ensure 415V power supply to the fan motor is disconnected before commencing commissioning. a. Check that all mechanical connections including safety cables and guy wires have been installed according to this guide. b. Ensure there are no physical obstructions that could be impacted by the rotating blades of the fan unit. c. Ensure all bystanders are cleared from the area during commissioning. d. Set Controller Unit to the Off position. e. Connect 415V supply to the fan motor. f. Switch the Controller Unit to MAN (Manual) operation. g. Set FAN SPEED on the Controller Unit to position 2. h. Switch the Controller Unit to the ON position. The fan motor is designed to ramp up to speed over a 90 second period. i. Once the fan achieves constant speed, increase the Control Unit FAN SPEED to test higher air movement velocities. j. Observe the operation of the fan to ensure there are no faults including mechanical noises and vibration. k. If the fan unit vibrates / oscillates as though out of balance or if there is any mechanical noise present, shut the fan down by switching the Control Unit to the OFF position before investigating further. Care and Maintenance Instructions The following maintenance instructions must be followed annually to ensure the safe operation of the fan. Attendance to maintenance requirements must be logged in a plant maintenance log book. Failure to follow these maintenance requirements voids the product warranty. WARNING: Turn off the fan and lock out power supply before performing maintenance. WARNING: When cleaning or attempting to re-torque you must unplug or disconnect the fan and controller from the power supply. Fan Hub and Blades: Dirt and dust may be removed from the blades by using a cloth or soft non-metallic brush. Stubborn stains may be removed with a cloth dampened with a mild detergent solution. Do not use strong solvents, Check the fan, including mount supports for bolts and nuts to make sure they are tight and show no wear and tear. Re-torque fasteners if required Check for oil leaks. Inspect 7mm lugs inside motor junction box and tighten if necessary. Using compressed air at 90~100 psi, blow all dust and debris off of the outside of the motor housing. Fan Controller: The fan controller should only require a wipe to remove dust and dirt. For heavier deposits, use a rag and a mild cleaning agent to clean the exterior of the control controller box. 10
Operating Instructions Fans operate in both summer cooling and as winter destratification modes. In summer cooling mode the fans operate by generating a cooling breeze of 0.5-1.5m s -1. This allows the body s natural cooling mechanisms to work more effectively, resulting in an apparent reduction in temperature of 4-6 o C. The fans do not affect the actual temperature of the air. There is a correlation between air velocity and apparent reduction in temperature until approx. 3m s -1 where the effect levels off and reduces. This means that the generation of a gentle breeze is more effective than creating higher velocity, and more focused air streams. In winter destratification mode the fans operate by mixing the warmer air that has collected at the top of a structure with the cold air below, increasing the ambient temperature of the space. This is achieved by running the fans at their minimum speed so that a nuisance breeze (wind chill) is not created. As the fans are operated with speed control, it is more efficient to run them slowly in a forward direction than to reverse the direction of the fan and keep the rotational velocity of the fan high. Operating Instructions 1) Choose control. If a temperature sensor has been fitted as part of the installation turn the MAN/AUTO switch to AUTO. If there is no temperature sensor set to MAN If set to MAN the fan speed is controlled by the potentiometer. Turn clockwise to increase the speed of the fan. 2) Turn the OFF/ON switch to ON The fan is designed with a 90 second ramp time. If the fan fails to start after 90 seconds turn off power and retry. 11