Installation Instructions
Contents
1. A 5 Installation Instructions 220V Single phase Input using ABB ACS550 VFD TABLE OF CONTENTS Page 3 Fan Placement Spacing and Clearance Page 4 Fan Maintenance Page 4 Installation Instructions Page 5 Control Keypad Instructions Page 16 Daisy aceon Page 20 MECHANICAL ITEMS INCLUDED IN YOUR SHIPMENT 5 Fan Blades 5 Fan Blade Flaps 5 Fan Blade End Caps 1 Fan Drive Assembly 1 Beam Mounting Bracket 7 Turnbuckles with jam nuts Gearbox Vent Must be installed Bolts nuts washers and clamps of various sizes see Installation Instructions for types and quantities ELECTRICAL ITEMS INCLUDED IN YOUR SHIPMENT 1 Lockable disconnect with installation instructions 1 5550 Variable Frequency Drive VFD with remote keypad One 1 VFD mounting bracket and hardware kit 100 ft of Cat 6 cable with RJ45 connectors Three 3 wire crimps for motor control cable One 1 Cat 6 cable strain relief One 1 Remote control keypad box One 1 ACS550 drive User s Manual One 1 motor control cable fan motor to VFD Two 2 motor cable strain reliefs SAFETY COMPONENTS PROVIDED Drive Assembly safety cable 12. wider than 7 should use slots labeled ii For beam thickness greater than gt gt use the provided spacer as shown in Image 2 Image 2 SPACER SPACER 4 3 4 CONNECTOR Attach clamp to structure torqueing GRADE 8 gt gt bolts to 80 ft lbs OPTIONAL When attaching the mounting bracket to added bridges between two or more points of an existing structure i e bar joists Z purlins etc orient the beam plate as shown in Image 3 This will ensure guy wire cables are properly aligned with the structure In this configuration the beam clamps will NOT be necessary Also longer GRADE 8 gt bolts are needed not provided Image 3 VFD BRACKET HOLES LONGER SIDE Using the hardware provided attach the VFD to the VFD bracket Then attach the VFD bracket combination to the mounting plate by means of the two 2 pre drilled holes see Image 3 A properly installed VFD is shown in Image 4 Image 4 Fan Assembly Mounting Bracket VFD Bracket Combo INSTALLER Please Note Customers may request that the VFD NOT be mounted on the fan so that it can be accessed It is important to emphasize that after installation there is no reason to get to the drive ALL of the information resets error codes and parameters are accessed from the remote keypad only If the customer insists Belden 29522C Multi Conductor 600V VFD cable should be used Failure to use proper VFD cable
3. may result in operational issues with the drive or fan and can shorten life expectancy vi If down rod was ordered remove the 4 connector and replace with the longer down rod Refer to Image 2 Step 2 Attach Fan Assembly to Mounting Hardware A Using a scissor lift raise the fan assembly and guide the connector or down rod into the tube on top of the fan frame until its mounting holes line up see Image 5 Image 5 Image 6 B Secure the fan to the swivel assembly or end of down rod as shown in Image 6 Torque bolts to 35 ft lbs Step 3 Install Fan Assembly Safety Cable Note This step is required Failure to install the safety cable may void the manufacturer s warranty A Pass one end of the safety cable underneath where the three vertical frame members join together at the top of the fan drive assembly The opposite end of the safety cable should be passed over the top of the or other mounting structure Connect the two ends of the cable together by means of 3 saddle clamps provided in the manner shown in Image 7 Tighten the saddle clamps securely using a gt socket Torque to 15 ft lbs Image 7 Step 4 Connect Both Ends of the Motor Control Cable Reference Pages 16 32 of the ACS550 User s Manual A Remove the cover of the VFD using the steps shown on page 17 of the ACS550 User s Manual under the heading IP 54 UL 12 B Remove the cable seals locat
4. Guy wires 3 Blade Safety Brackets 5 TOOLS TO GET STARTED Scissor lift Wrench socket set 5 16 3 4 needed Cordless power driver with clutch and Phillips Bit 1 4 Nut driver Torque wrench Standard and Phillips screwdrivers Instrument screwdriver 1 8 flat blade Wire stripper cutter Level 3 16 L shaped Allen wrench Three 3 beam clamps with eye bolts Check that all necessary parts are included with your shipment Should an item be missing contact Patterson immediately at 800 768 3985 Note order to protect personnel equipment and the fan it is important that all safety components are installed per these instructions Failure to properly install any or all of these safeguards may void the manufacturer s warranty Electrical installation should be performed by a licensed electrician FAN SPACING PLACEMENT AND CLEARANCE Fans should be mounted such that the blades are a minimum of 10 feet above the floor The ideal height is 20 to 25 feet Also ensure that the fan blades have a clearance equal to 15 of the fan s diameter in all directions Care should be taken when installing the fan around a fire sprinkler system The VFD is equipped with the ability to connect to a fire suppression system stopping the fans in case of a fire However it is the responsibility of the installer to read and comply with all local codes and regulations MAINTENANCE Prior to performing any mainten
5. PM see 4 above Fan motor amperage Indicates the current being drawn by the fan motor expressed in Amperes A c Fan motor torque Indicates fan motor output torque expressed in percentage Soft Keys Located directly below functions displayed in the lower corners of the keypad screen Right Soft Key is generally not used during basic fan operation Left Soft Key controls fan direction See section entitled Additional Information Up Down Arrows Allow for adjustment of the Fan Speed Set Point either while the fan is stopped or in motion See section entitled Fan Operation LOC REM Button Toggles between local and remote control of the fan drive If LOC is displayed in the upper left corner of the keypad screen control of the drive is initiated locally i e from the keypad If REM is displayed control is initiated from an external source i e another drive or fieldbus Help Button Provides more information during drive programming Not used for fan operation 10 Start Stop Buttons Used to start and stop the fan See section entitled Fan Operation 18 OPERATION Starting the Fan 1 sure the LOC REM Indicator shows the fan drive is local LOC mode The fan will not respond to inputs from the keypad if the drive is in remote REM mode Use the LOC REM Button as needed to ensure local control Using the Up Down Arrow keys adjust the Fan Speed Set Point Remember the Fan Speed
6. Set Point is based on percentage of maximum speed This percentage corresponds to the read only RPM indicator Press the START button and allow the fan to ramp up to speed This may take a few seconds To prevent damage to the gearbox it is recommended that the fan reach its Set Point speed before making any further adjustments If the initial Set Point adjustment is unsatisfactory refer to the section below entitled Adjusting Fan Speed While in Motion to achieve the desired fan RPM Adjusting Fan Speed While in Motion 1 Ensure local LOC control of the drive see above 2 Use the Up Down Arrow keys to adjust the Fan Speed Set Point as desired For best results use the Read Only Fan Speed indicator in RPMs as a gauge for your desired setting The fan will then ramp up or down in response to the changing input Caution DO NOT adjust the Fan Speed up and down repeatedly in large increments Allow the fan to reach the new speed before making any further adjustments Stopping the Fan 1 Ensure local LOC control of the drive see above Press the STOP button The fan will then ramp down to a complete stop This may take a few seconds Allow the fan to stop COMPLETELY before restarting 19 ADDITIONAL INFORMATION 1 Fan drives are programmed prior to shipment In order to ensure continuity drive parameters are locked by means of a three digit passcode Should troubleshooting of the drive become necessa
7. afety Bracket A Care should be taken when installing the blades to ensure they are not bent or damaged as this may affect fan performance Remove blade bolts nuts and washers from blade paddle the fan s hub Loosen Safety Bracket bolt shown in Image 13 until the bracket moves freely Carefully slide the fan blade into position until all blade bolt holes on the fan blade and safety bracket are aligned Replace blade bolts nuts and washers Torque to 65 ft lbs C Tighten the 3 8 Safety Bracket bolt on the other end of the blade safety bracket Image 13 D Install blade flaps using bolts and end caps using 10 x screws provided Ensure bolts are tight on flaps pan head of the bolts go into the countersinks in the bottom of the blades Refer to Image 14 for more information 13 Repeat steps D for the remaining 4 blades Step 8 Remove Plug in Cap of Gearbox Note This step is required Failure to remove the plug may cause gearbox seals to leak due to pressurization of the lubrication fluid possibly voiding the manufacturer s warranty A Remove plug in the gearbox and replace with vent prior to operation of the fan The vent fitting is in a bag that is affixed to the frame at the location of the plug Step 9 Mount the Remote Keypad Enclosure and Connect to VFD Note It is vitally important that the remote keypad is ALWAYS mounted outside the blade radius of th
8. ance on the fan it MUST be disconnected from the power source by means of the separate lockable disconnect provided VFD Box Clean heat dissipating fins on the back of the box periodically Gearbox Periodic maintenance will ensure your fan remains operational for its intended life While Patterson recommends the end user check and change the gearbox oil annually failure to do so will not void any warranties Oil type used is Chevron Delo Gear ESI 85W 140 Contact Patterson at 800 768 3985 for availability Hub Grease Hub should be inspected yearly to ensure proper lubrication Grease type is Chevron Delo HD Moly 5 There are two grease fittings an upper and lower Add grease as needed filling each area slowly until grease passes through the upper seal Mounting Hardware All nuts and bolts related to mounting of the fan unit should be checked for tightness annually In addition guy wires need to be inspected to ensure they remain taut and show no signs of fraying Blades Blades be occasionally wiped down with a damp cloth A mild detergent can also be used if desired INSTALLATION PROCEDURES Step 1 Attach Mounting Bracket and VFD Bracket to Structure A It is important to attach the mounting bracket to the structure first and then connect the fan assembly B Refer to Image 1 to determine which set of bolt slots to use Image 1 i For l beam width less than 7 use slots labeled
9. anufacturer s warranty AND become a safety hazard The following steps should be performed with the aid of a scissor lift Image 9 A Attach the looped end of the guy wire to the turnbuckle located on the fan assembly It should appear like the Image 10 Image 10 11 Pass the opposite end of the guy wire through the eye bolt of a beam clamp not supplied Thimbles must be used to protect the cable from damage C Reduce the slack in each cable making sure the fan assembly remains in the vertical position Use 3 saddle clamps to crimp the end of the guy wire together as shown in Image 11 Ensure saddle clamps are positioned so that the teeth on the nut side grab the end of the cable that is most likely to slip Image 11 D Repeat steps for the remaining two guy wires E Once all guy wires are in place use the turnbuckles to take out any remaining slack Periodically check the fan assembly with a level to ensure it remains in the vertical position Continue adjusting by means of the turnbuckles until all cables are satisfactory Guy wires should be taut but not over stressed Recheck all saddle clamps for tightness T Tighten all jam nuts on turn buckles Image 12 This step is required Failure to install the guy wires properly may void the manufacturer s warranty AND become a safety hazard Image 12 m JAM NUTS 12 Step 7 Install Blades amp Secure Blade S
10. at fan NOT the designated master Each follower must be wired according to the diagram on page 21 The VFD designated as the master will be wired in exactly the same manner but without wiring ANYTHING into terminals 2 and 3 on the VFD 20 Connection example X1 From upstream 1 SCR Signal cable shield screen j External frequency reference 1 0 10 To Downstream Drive 3 AGND Analog input circuit common 4 10V Reference voltage 10 V DC 2 Not used 6 AGND Analog input circuit common AQI Output frequency 0 20 mA 8 2 Output current 0 20 mA 9 AGND Analog output circuit common 110 24V Auxiliary voltage output 24 DC 11 GND Auxiliary voltage output common DCOM Digital input common for all 13D Start Stop Activate to stalt 114 012 Fwd Rev Activate to reverse rotation direction 15 1013 Constant speed selection 146 DI4 Constant speed selection 17 1015 Ramp pair selection Activate to select 2nd acc dec ramp pair 18 DI6 Not used 419 1 Relay output 1 programmable 20 Default operation 21 RO1B Ready gt 19 connected to 21 22 RO2C Relay output 2 programmable 23 RO2A Default operation Running gt 22 connected to 24 25 RO3C Relay output 3 programmable Default operation 207 Fault 1 gt 25 connected to 27 Fault gt 25 connected to 26 K
11. e fan This is especially important for the daisy chaining configuration see page 20 The daisy chaining process requires access to the keypad while the fan is in motion A Once a desired location is found affix the remote keypad to the wall using the mounting pads attached to the keypad enclosure B Run the Cat 6 cable up to the fan mounted VFD via the shortest possible path If possible avoid lighting and other noise producing electrical equipment Running the cable inside conduit is optional 14 Pass the Cat 6 cable through the strain relief and then into the bottom of the drive Connect the cable to the appropriate receptacle on the face of the VFD see Image 8 on page 10 Be sure to tighten the strain relief on the bottom of the VFD D Replace the cover of the VFD using the steps show on page 32 of the ACS550 User s Manual under the heading IP 54 UL 12 Step 10 Connect the VFD to the Fire Suppression System OPTIONAL Please Note If the drive will not be connected to any fire suppression system the factory installed jumper across 10 amp 16 MUST remain in place A Remove the factory installed jumper between terminals 10 and 16 The terminal block is located at the left side of the ACS550 For more information refer to Image 8 on page 10 B Connect the fire suppression system wires to terminals 10 and 16 Again the fire system cable will enter the drive enclosure through the bottom additio
12. ed on the bottom of the drive as needed A total of three cable seals must be removed to accommodate the motor cable power cable and Cat 6 cable C Pass the cable conductors and shielding through one of the provided strain reliefs and then through one of the holes on the bottom of the VFD D Connect one end of the motor control cable to the VFD in the manner shown on page 29 of the ACS550 User s Manual The three conductors should be connected to U2 V2 and W2 respectively using the three 3 yellow wire crimps The cable foil shield should be secured by the cable clamp as shown in Image 8 w Connect the opposite end of the motor control cable to the fan motor This will require removal of one of the knockouts on the motor s junction box As before pass the cable conductors and shielding through the strain relief and then through the junction box hole The wiring configuration is input voltage dependent Please wire the motor properly using the wiring diagrams found on the fan motor s nameplate F Once cable is properly connected at both ends tighten down the strain reliefs Step 5 Run Input Power to Drive and Install Lockable Disconnect References Pages 16 32 of the ACS550 User s Manual Lockable Disconnect Installation Instructions WARNING The Lockable Disconnect must be installed per local electrical codes AT MINIMUM it must be installed outside the diameter of the fan blades A Run input power into the to
13. ey Points for Daisy Chaining Wire for daisy chaining must be 2 conductor with ground 18 AWG double shielded Based on the wiring diagram please note that only the to downstream drive end of the daisy chain wire shield is connected to the drive at terminal 1 The shield on the input side terminals 2 and 3 is not connected Please note the series of jumpers in the above diagram These must be connected in addition to the daisy chain input output wiring Two of the jumpers are already factory installed see below The rest must be connected at the time of fan installation The numbers in the diagram correspond to numbers on the drive s terminal block see Image 8 on page 10 of these instructions Factory installed jumpers 11 amp 12 10 amp 16 Field installed jumpers 10 amp 19 10 amp 22 13 amp 20 13 amp 23 21 4 Make sure that the DIP switch labeled 1 is in the ON or right position This switch is located above I O terminal block 1 Refer to Image 8 on 10 for more information 5 To reduce noise and potential drive interruption it is recommended that daisy chain wire be run through conduit 6 Speed scaling Because of line losses downstream followers may initially rotate at a slower speed than that of the master To rectify this problem perform these steps Make sure the master is in LOCAL mode and all followers REMOTE mode If it is safe
14. nal cable seal must be removed C Drive is now wired to shut down upon activation of any fire suppression signal This completes the installation of your High 5 Fan 4 HIGH 5 15 Fan Control Keypad Instructions HIGH 5 CAUTION Please read carefully and completely before fan operation FAN ROTATION Proper rotation is achieved when the directional indicator 3 in Image 15 is clockwise and the blade flaps are trailing If rotation is not correct swapping two of the motor wires L1 L2 or L3 in the motor junction box will change the rotation 16 15 17 CONTROL KEYPAD FEATURES 1 9 Status LED a Green Normal Operation b Blinking Green Fan drive is in alarm Consult the drive s User Manual for alarm conditions Red drive has faulted Consult the drive s User Manual for fault conditions LOC REM Indicator Indicates whether the drive is in local or remote control See LOC REM button entry below for more detail Rotation Indicator Indicates rotation of the fan motor shaft and fan blades See item 2 in the section entitled Additional Information Fan Speed Set Point Indicates fan speed as a percent of maximum This percentage corresponds to a read only RPM reading see 5 below Can be adjusted using the up and down arrows see 7 below Read Only Parameters Give real time readouts of the following conditions Fan speed Expressed in R
15. p of the Lockable Disconnect using the appropriately sized knockout B Connect conductors to terminals L1and L2 respectively Ground wire should be fastened to the protective earth PE C On the output side T2 should be looped back to input L3 D Continue running input power to the drive by connecting two conductors to terminals T1 and T3 respectively A ground wire should be fastened to the protective earth PE provided Connect the opposite end of the input power cable to the VFD in the manner shown on page 29 of the ACS550 User s Manual The two conductors should be connected to U1 and W1 respectively The ground wire should be connected in the manner shown in Image 8 F A successfully wired drive should appear like Image 8 Image 8 Cat 6 Cable a Receptacle 012A 2 BO Wi VFD I O SIN 2132700769 Terminal Blocks Factory Installed Jumpers Warning Dangerous voltage Wait 5 minutes after disconnecting supply before proceeding Seo Usor s Manual BIOS 25 69 EES FEA EE 4 4 i al 3 Input Voltage we Input Voltage 227 7 Ground Wire 1 Motor Control 4 A j Cable Shielding 2 10 Step 6 Install Guy Wires Note For maximum stability the angle formed between the guy wire and the ceiling should be less than 45 degrees This step is required Failure to install the wires properly may void the m
16. ry contact Patterson at 800 768 3985 A passcode can then be given to unlock the drive s parameters It is highly recommended that the parameters be relocked using the same passcode prior to putting the fan back in service 2 Patterson s High 5 fans are designed to maximize air movement while spinning in the FORWARD direction However they can be run in REVERSE Follow these steps a If the fan is stopped press the left Soft Key with the letters DIR above it When the fan is started it will run in the reverse direction b If the fan is running press the STOP button and allow the fan to come to a complete stop Then press the left Soft Key with the letters DIR above it When the fan is started it will run in the reverse direction 3 Please be aware that each fan is programmed to have a minimum fan speed set at some level above 0 This is to protect the fan motor The minimum speed will vary depending on the size of the fan Daisy Chaining Daisy chaining is a set up by which the output of one VFD is tied the input of the next VFD downstream This allows for a master follower configuration The master fan remains in LOCAL mode while all the followers are set to REMOTE The followers will then rotate at the same speed as the master fan Note Any fan in the daisy chain can be set to LOCAL LOC mode for local control However all of the fans downstream will then begin to rotate at the speed of th
17. to do so turn the master fan on to maximum speed All fans should begin spinning at this time Note the maximum speed on the master unit s keypad in RPMs a Go to the first downstream follower If the unit is rotating at the same speed as the master no additional action is necessary However if the speed is slower than the master go to Step b b Unlock the follower s parameter set i ii iii vii viii Set the fan in local mode by pressing the LOC REM button Press the MENU key on the keypad Highlight the PARAMETERS option Press ENTER Use the up down arrow keys to highlight parameter group 16 Press SELECT Scroll down to parameter 1603 PASS CODE Enter the pass code shown next to the parameter s description on page 125 of the 5550 User s Manual You will use the up down arrow keys to enter the code Once entered press the SAVE key Scroll up and select parameter 1602 PARAMETER LOCK Using the arrow keys change the status from LOCKED to OPEN Press the SAVE key Continue pressing the EXIT key until you arrive at the keypad s output screen Return the fan to REMOTE mode by pressing the LOC REM button Go to Step c c Once the parameter set has been unlocked the fan speed will need to be scaled to match that of the master To accomplish this iv vi vii Press the MENU key on the keypad Highlight the PARAMETERS option Press ENTER Use the up down arro
18. w keys to highlight parameter group 01 Press SELECT Scroll down to parameter 0120 Al 1 This is a read only parameter Jot down or remember its value expressed as a percentage Press EXIT until you reach the keypad output screen Place the fan in LOCAL control by pressing the LOC REM button Navigate back to parameter group 13 Press SELECT Find parameter 1302 MAXIMUM Al1 Using the arrow keys enter the percentage from parameter 0120 Press the SAVE key 22 Press EXIT until you reach the keypad output screen Return the fan to REMOTE mode The fan should immediately start to up to match the master d Repeat Steps b for each additional downstream follower It is advisable to re lock each fan s parameter set after adjusting the speed scale reversing the instructions in Step b This will prevent unnecessary tampering with fan drive parameters e Once all followers have been properly scaled return to the master fan and set the desired speed for the daisy chained system For additional questions concerning the daisy chain configuration contact Patterson engineering at 800 768 3985 This completes the High 5 Keypad Instructions AY HIGH 5 23
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