CaptiveAire HVLS User manual

A0025729
September 2020 Rev. 14
High Volume Low Speed (HVLS) Fan
HVLS and General Ventilation Fan Control Software
Installation, Operation, and Maintenance Manual
Save these instructions. This document is the property of the owner of this equipment and is required for
future maintenance. Leave this document with the owner when installation or service is complete.
RECEIVING AND INSPECTION
Upon receiving the control package and/or fans, check for any interior and exterior damage, and if
found, report it immediately to the carrier. Check that all accessory items are accounted for and
free of damage.
WARNING!!
Installation of this fan and control package should only be performed by a qualified professional
who has read and understands these instructions and is familiar with proper safety precautions.
Improper installation poses a serious risk of injury due to electric shock, contact with rotating
equipment, and other potential hazards. Read this manual thoroughly before installing or
servicing this equipment. ALWAYS disconnect power prior to working on fans.
HVLS/VENT
MENU UP DOWN ENTER
SW1 SW2 SW3 SW4

2
Table of Contents
WARRANTY .............................................................................3
HVLS Extended Warranty ...................................................3
Warranty Conditions ............................................................4
INSTALLATION ........................................................................5
Mechanical ..........................................................................5
Main Control Enclosure Installation .................................5
Site Preparation – Controls ..............................................5
Hardware Torques ..............................................................6
Remote Room Sensor/HMI Installation ............................7
Room Temperature Sensor .............................................7
HVLS Fan Clearance ..........................................................8
Fan Located Below HVAC Discharge or Intake ...............8
Fan Located At or Above HVAC Discharge or Intake ......9
Fan Located Near Lighting Sources ................................9
Site Preparation - Fan .......................................................11
Fan Mounting Configurations ............................................11
I-Beam Mount ....................................................................12
Concrete Beam Direct Mount ............................................13
Concrete Multi-Beam Mount .............................................14
Wood Beam Direct Mount .................................................15
Open Web Steel Joist Mount(s) ........................................17
Direct Beam Mount ........................................................17
Installing Fan Between OWSJ .......................................18
Mounting Between OWSJ .................................................19
Purlin Mount ......................................................................23
Installing Pivot Mount Assembly .......................................25
Tube Assembly .................................................................26
Leveling Pivot Assembly ...................................................27
Hub Assembly ...................................................................28
Mounting Fan to Extension ...............................................29
Guy Wire ...........................................................................30
Clamp Installation ..........................................................30
Guy Wire Installation ......................................................30
Blade Installation ...............................................................32
Electrical ............................................................................33
High Voltage Wiring ..........................................................34
VFD Wiring ........................................................................34
Variable Frequency Drive (VFD) .......................................36
VFD Installation ..............................................................37
Input AC Power ..............................................................37
VFD Output Power .........................................................37
VFD Programming .........................................................38
ACTECH SMV VFD .......................................................39
Low Voltage Wiring ........................................................40
OPERATION ..........................................................................41
Smart Control Functionality ...............................................41
Summary of Fan Control ................................................41
Automatic Mode .............................................................41
Scheduling ........................................................................43
Manual Mode ....................................................................43
Start-up Procedure ............................................................45
Start-up Procedure - Fans .............................................45
Start-up Procedure – Smart Control ..................................45
Manual Mode Startup .....................................................47
Automatic Mode Startup .................................................48
HMI Configuration .............................................................49
General Overview ..........................................................49
Editing HMI Number and Contrast ....................................49
Input Simulation .............................................................49
HMI Configuration Details .................................................50
HMI Menu System Overview .............................................51
HMI Menu Tree ..............................................................51
ECPM03 Configuration ......................................................52
General Overview ..........................................................52
Product Mode .................................................................52
ECPM03 Menu System Overview .....................................53
ECPM03 Configuration Details ......................................53
ECPM03 Menu Tree ......................................................56
ECPM03 Board .................................................................57
Connector Descriptions ..................................................57
Building Management System ...........................................60
Emergency Shutdown Interlock .........................................60
Manual/Auto Mode from HMI (Lowest Priority) ..............60
Low Voltage BMS Interlock ............................................61
High Voltage BMS Interlock ...........................................61
Network .............................................................................62
BACnet ...........................................................................62
Device Instance, MAC Address, Baud Rate ..................63
Changing the IP Address ...............................................64
LonWorks .......................................................................65
Direct Digital Control (DDC) ..............................................66
Troubleshooting .................................................................70
VFD Fault List ................................................................71
HMI Fault List .................................................................72
MAINTENANCE .....................................................................73
General Maintenance ........................................................73
Every 3 Months .................................................................73
6 Months After Startup ......................................................73
Every 12 Months ...............................................................74
Every 36 Months ...............................................................74
Maintenance Logging and Alerts .......................................74
Start-Up Documentation ....................................................76

3
WARRANTY
This equipment is warranted to be free from defects in materials and workmanship, under normal use and
service, for a period of 5-years from date of shipment. This warranty shall not apply if:
1. The equipment is not installed by a qualified installer per the MANUFACTURER’S installation
instructions shipped with the product.
2. The equipment is not installed in accordance with Federal, State, or Local codes and regulations.
3. The equipment is misused or neglected, or not maintained per the MANUFACTURER’S maintenance
instructions.
4. The equipment is not installed and operated within the limitations set forth in this manual.
5. The invoice is not paid within the terms of the sales agreement.
The MANUFACTURER shall not be liable for incidental and consequential losses and damages potentially
attributable to malfunctioning equipment. Should any part of the equipment prove to be defective in
material or workmanship within the 5-year warranty period, upon examination by the MANUFACTURER,
such part will be repaired or replaced by MANUFACTURER at no charge. The BUYER shall pay all labor
costs incurred in connection with such repair or replacement. Equipment shall not be returned without
MANUFACTURER’S prior authorization, and all returned equipment shall be shipped by the BUYER,
freight prepaid to a destination determined by the MANUFACTURER.
NOTE: To receive warranty coverage, copy and print the “Start-Up Documentation” on page 76. Fill
out the form, then fax the form to 1-919-516-8710 or call 1-866-784-6900 for email information within
thirty (30) days of purchase.
HVLS Extended Warranty
ATTENTION: If the fan is damaged during operation, the fan SHOULD NOT be operated until a
factory authorized representative has inspected and approved the repair or replacement of parts.
What this warranty does not cover, any defects or damage caused by:
• Objects that come in contact with the fan causing damage.
• Objects that become tangled with the fan (e.g., power cords, extension cords, air hoses, chains, etc.).
• Premises structural defects, structural movements or settlement.
• Parts and/or components damaged from neglect, accident, abuse, misuse, misapplication, or incorrect
installation.
• Repair or alteration not authorized in writing by the MANUFACTURER.
• Failure to properly store the product before installation.
• Exposure to caustic chemicals, saltwater, acidic or corrosive elements, excessive humidity, or windy
conditions.
• Improper testing, operation, maintenance, adjustment, or modification of any kind not authorized in
writing by MANUFACTURER personnel.
• Use of the product under other than normal operating conditions or in a manner inconsistent with the
product’s label or instructions such as:
• Controls and or any other external electronic controlling devices.
• Exclusions listed in the standard or extended warranties.
• Any products or components purchased prior to effective date of this warranty.
• Shipping and delivery of the product through the shipping carrier.
Factory Authorized Representative Installation
7-Year Warranty:
Electrical and Mechanical components Lifetime Warranty: Blades, Hub, and Frame

4
Warranty Conditions
This warranty is not valid:
• Unless the USER returns to the MANUFACTURER the “Start-Up Documentation” on page 76 within
thirty (30) days of purchase.
• If the product’s serial numbers have been removed or are illegible.
• If any warranted items repaired or replaced pursuant to this warranty will be warranted for the
remaining portion of the original warranty subject to all the terms thereof. The MANUFACTURER shall
not be responsible for any charges for testing, checking, removal, or installation of warranted items
unless authorized in writing by MANUFACTURING personnel.
• If failed to submit records at the time of performing recommended Maintenance Schedule, minimum
every 18 months.
Limitation of liability: The remedies of the USER set forth herein are exclusive and are the sole remedies
for any failure of the MANUFACTURER to comply with its obligations hereunder. In no event shall the
MANUFACTURER be liable in contract, in tort (including negligence or strict liability) or otherwise for
damage to property or equipment other than the products, including loss of profits or revenue, loss of use
of products, cost of capital, claims of customers of the USER or any special, indirect, incidental or
consequential damages whatsoever. The total cumulative liability of the MANUFACTURER hereunder
whether the claims are based in contract (including indemnity), in tort (including negligence or strict
liability) or otherwise, shall not exceed the price of the product on which such liability is based. The
MANUFACTURER shall not be responsible for failure to provide service or parts due to causes beyond the
MANUFACTURER’S reasonable control.
USER'S obligations: In order to receive the benefits of this warranty, the USER must use the product in a
normal way, follow the product's installation manual, and protect against further damage to the product if
there is a covered defect. Submit records at the time of performing RecommendedMaintenance Schedule,
minimum every 18 months.
Other limitations: The MANUFACTURER’S obligations under this warranty are expressly conditioned
upon receipt by the MANUFACTURER of all payments due to it, including all applicable interest charges.
During such time as the MANUFACTURER has not received payment of any amount due to it for the
product, in accordance with the contract terms under which the product is sold, the MANUFACTURER
shall have no obligation under this warranty. Also, during such time, the period of this warranty shall
continue to run, and the expiration of this warranty shall not be extended upon payment of any overdue or
unpaid amounts.
Costs not related to warranty: The USER shall be invoiced for and shall pay for all services not expressly
provided for by the terms of the warranty, including without limitation, site calls involving an inspection that
determines no corrective maintenance is required. Any costs for replacement equipment, installation,
materials, freight charges, travel expenses, or labor of the MANUFACTURER’S representatives outside
the terms of this warranty will be borne by the USER.
Obtain warranty service: Call the Factory Service Department at 1-866-784-6900, or fax [phone]-
9374. The MANUFACTURER will not accept any products for return, credit, or exchange unless expressly
authorized by the MANUFACTURER in writing and delivered to the MANUFACTURER’S factory service
location with proper Return Authorization Number attached to the product.

5
INSTALLATION
It is imperative that this unit is installed and operated with the designed speed range and electrical supply
in accordance with this manual and applicable codes. If there are any questions about any items, please
call the service department at 1-866-784-6900 for warranty and technical support issues.
WARNING: TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT BEND THE BLADE BRACKETS
WHEN INSTALLING THE BRACKETS, BALANCING THE BLADES, OR CLEANING THE FAN. DO
NOT INSERT FOREIGN OBJECTS IN BETWEEN ROTATING FAN BLADES.
Mechanical
WARNING: DO NOT LIFT CONTROL BY WIRING COMPONENTS. DO NOT LIFT FAN BY THE
BLADES, MOTOR SHAFT OR BEARINGS. TORQUE ALL FASTENERS PER THIS MANUAL.
Tools Required: Level, Basic wrench set, Basic socket set (up to 3/4”), Cable cutters, Lifting device or
scaffolding, Ratchet or impact gun, Torque Wrench
Main Control Enclosure Installation
The control panel enclosure must be secured to a fixed wall near the fan. Maintain adequate clearance
from excessive heat sources, such as appliances or processing equipment, to prevent damage to
the components.
There are four pre-punched holes in the backside of the control enclosure. Use suitably sized mounting
hardware to attach to the wall.
Site Preparation – Controls
• Provide clearance around installation site to safely install equipment into its final position. Supports
must adequately support equipment. Refer to manufacturer’s estimated weights.
• Consider general service and installation space when locating the control package and remote
temperature control.
• Locate the control as close to space/fan that it will serve to reduce long, unnecessary wire runs.
• Install thermostats in locations that will produce a good representation of the air being moved by the
fan in the space. Avoid thermostat installations in direct sunlight, near HVAC supplies, or abnormal
temperature air streams.
• Refer to Figure 1 on page 6 for typical control panel layout.

6
Figure 1 - Control Panel Layout
Hardware Torques
Table 1 - Torques
Thread Size Torque
1/8” Clamp 3 Ft-lbs (36 in-lbs) / 4 Nm
3/16” Clamp 4.5 Ft-lbs (54 in-lbs) / 6 Nm
3/8” Grade 8 Min 30 Ft-lbs / 41 Nm
M10 Class 8.8 Min 38 Ft-lbs / 52 Nm
1/2” Grade 8 Min 75 Ft-lbs / 101 Nm
M14 Class 8.8 Min 105 Ft-lbs / 142 Nm
8, 12, 16 Torque Nut 190 Ft-lbs / 257 Nm
20, 24 Torque Nut 265 Ft-lbs / 359 Nm
Cooling Fan
VFD mounted inside
panel. VFD may also be
mounted on fan.
High Voltage
Terminals
Low Voltage
Terminals
ECPM03
Protonode
(Optional)

7
Remote Room Sensor/HMI Installation
Do not install the room sensor on the ceiling.
Smart controls, remote room sensors, and remote HMI (Human Machine Interface) faceplate(s) may be
ordered and shipped separately. These components measure temperature and assist in controlling the
unit. These components should be installed in a safe location, free of influence from external heat sources,
and should be indicative of the average room temperature away from heat-producing appliances. HMIs
and remote room sensors (Figure 2) can be installed directly to industry-standard junction boxes, either
surface mounted or recessed mounted. HMIs have a built-in temperature sensor, which is typically used to
help control the automatic function of the unit. The HMI can also be configured to control the unit from a
remote location manually. They can be configured not to use the internal temperature sensor. In this
configuration, the sensor in the HMI is ignored in automatic operation. Multiple HMIs can be connected to
one unit for temperature and R/H averaging. Control modes will be discussed in later sections of this
manual.
Room Temperature Sensor
The room temperature sensor is a 10K ohm thermistor. The sensor provides constant room temperature to
the controller. It should be installed on a wall somewhere in the room, but not directly in the path of HVAC
diffusers or close to heat-producing appliances so that the reading is not affected by heat.
Room sensors are not required for proper control operation but can be configured to be used as remote
sensors or averaging sensors.
Figure 2 - Remote Room Sensors
5-1/2”
5-1/2”
HMI Mounted to Junction Box Remote Room Sensor

8
HVLS Fan Clearance
NOTE: Make sure the fan is not installed above any objects that produce airflow toward fan blades.
Clearances:
• 60” minimum top of fan blade to roof deck
• 24” minimum from fan blade to obstructions above or below
• 18” minimum from side of fan to any obstruction
• 144” minimum from floor to fan
Fan Located Below HVAC Discharge or Intake
A fan that is mounted below a discharge/intake diffuser must be located greater or equal to 2x the fan’s
diameter. For down discharge, the distance must be greater or equal to 1/2 the fan’s diameter.
Figure 3 - Fan Located Below HVAC Details
Fan Blade Diameter (Feet) Clearance (Feet)
612
816
10 20
12 24
14 28
16 32
18 36
20 40
22 44
24 48
DISTANCE MUST BE GREATER OR
EQUAL TO 2x THE FAN'S DIAMETER
DISCHARGE/
INTAKE DIFFUSER
GUY
WIRES
STANDARD MOUNT
(AVA ILABLE IN 12", 24"
OR 48" LENGTHS)
OPTIONAL EXTENSION
(AVAILABLE IN 24" OR 48"
LENGTHS)
2 MAX PER FAN
D
B
C
A
A. Guy wire angle distance = 45° to 60°
B. Distance from extension mount to top of fan = 21-1/2”
C. Distance from extension mount to bottom of fan = 25”
D. Distance from ceiling to fan = Minimum 60”

9
Fan Located At or Above HVAC Discharge or Intake
A fan that is mounted at or above the discharge/intake diffuser must be located greater or equal to the
fan’s diameter. For down discharge, the distance must be greater or equal to 1/2 the fan’s diameter.
Figure 4 - Fan Located At or Above Discharge or Intake Details
Fan Located Near Lighting Sources
There are various lighting variables that may cause a strobing effect. Figure 5 illustrates lighting scenarios
to consider when mounting an HVLS fan.
Lights mounted above an HVLS fan can create a strobing effect if the beam (A) passes through the blades.
To minimize strobing effects, increase the vertical distance (B) between the light source and fan blades.
Increasing the horizontal distance (C) between the blade tips and light source will also help to alleviate
strobing effects. Figure 5 - Clearances to Lighting Sources
D
STANDARD MOUNT
(AVA ILABLE IN 12",
24" OR 48" LENGTHS)
A
DISCHARGE/
INTAKE DIFFUSER
C
B
DISTANCE MUST BE GREATER OR
EQUAL TO THE FAN'S DIAMETER
E
WIRES
GUY
A. Distance from top fan blade to bottom joist = Minimum 24”
B. Distance from extension mount to top of fan = 21-1/2”
C. Distance from extension mount to bottom of fan = 25”
D. Guy wire angle distance = 45° to 60°
E. Distance from ceiling to fan = Minimum 60”
B
C
Light
A
Light

10
Figure 6 - Fan Clearance Details
HVLS fans installed in buildings equipped with sprinklers, including ESFR (Early Suppression, Fast
Response) sprinklers, shall comply with the following:
• The maximum fan diameter shall be 24 ft (7.3 m).
• The HVLS fan shall be centered approximately between four adjacent sprinklers. The vertical
clearance from the HVLS fan to sprinkler deflector shall be a minimum of 3 ft. (0.9 m).
• All HVLS fans shall be interlocked to shut down immediately upon receiving a water-flow signal from
the alarm system in accordance with the requirements of NFPA 72.
NOTE: Contractor is responsible for verifying all site conditions to include field dimensions where
applicable. If the contractor elects to make any changes without notification, the contractor is
responsible for the changes. All drawings are to be used as general architectural intent unless
otherwise stamped. See engineering drawings for structural design information. Contractor to
ensure that all building departments and authorities are informed concerning the work, and all
permits are obtained before beginning work.
24” 26”
Fan Frame
Sloped Roof
48” Min
144”
24”
18”
24”
60”
Flat Roof
= Obstruction