Greenheck vari-green Instruction manual

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!
1
Vari-Green Motor
Table of Contents
Reference part number listed in chart to locate specific motor
information page number.
HP Voltage * RPM
Range Encl. FLA Control Method
Motor
Part No. Pg.
1/6 115 300-1725 TENV
3.1 0-10V Only 311352 2
3.1 Pot Only 311353 2
3.4 Pot/0-10V 311731 3
312359 3
1/4 115 300-1725 ODP
3.9 0-10V Only 310107 2
3.9 Pot Only 310108 2
3.7 Pot/0-10V 311377 3
1/4 115/
208-230 300-1725 ODP 3.3/1.8 Pot/0-10V 310175 6
1/2 115 300-1725 ODP
6.2 0-10V Only 309025 2
6.2 Pot Only 309028 2
6.7 Pot/0-10V 311812 3
1/2 115/
208-230 300-1725 ODP 6.8/3.5 Pot/0-10V 310176 6
1/2 115 300-2500 ODP
6.5 0-10V Only 310307 2
6.5 Pot Only 310476 2
6.5 Pot/0-10V 312360 3
3/4 115 300-1725 ODP
10.1 0-10V Only 309026 2
10.1 Pot Only 309029 2
10.6 Pot/0-10V 311388 3
312619 3
3/4 115/
208-230 300-1725 ODP 9.0/4.9 Pot/0-10V 310177 6
3/4 115 300-2200 ODP
11.3 0-10V Only 310306 2
11.3 Pot Only 310475 2
11.3 Pot/0-10V 312361 3
1 115 300-1725 ODP 12.4 Pot/0-10V 310359 3
312362 3
1115/
208-230 300-1725 ODP 11.4/6.3 Pot/0-10V 310178 6
1115/
208-230 300-1725 TEFC 12.0/6.0 Pot/0-10V 311156 4
2 208-230 300 - 1725 TEFC 12.0 Pot/0-10V 310420 4
*Actual maximum RPM may vary. See RPM column in chart on
pg.10 for specific motor and fan combinations.
Vari-Green®Motor
The Vari-Green Motor is an electronically commutated
(EC) motor that uses AC input power and internally
converts it to a DC power supply which provides an
80% turndown capability and increased energy savings.
NOTE
When using a clamp meter to measure input amp
draw, the meter must be capable of reading a
non-linear current. Erroneous readings will occur
otherwise.
Troubleshooting ...........................7-9
Maximum RPM Table ....................... 10
®
®
Document 473681
Vari-Green®Motor and Controls

2Vari-Green Motor
Operation and Wiring
- Potentiometer Dial Only
These motors feature a potentiometer dial on the motor
for speed adjustment. A small screwdriver can be used
to make the speed adjustment. To increase the speed,
rotate the dial clockwise. To decrease the speed, rotate
the dial counter clockwise.
The motor is pre-wired at the factory and cannot be
changed inside the motor. Connect single-phase power
at the voltage listed on the nameplate.
These motors cannot be converted to receive a remote
control signal – a different motor is needed. Please
consult the factory.
Features, Operation,
Wiring and Troubleshooting
Features
Soft start – All motors
feature soft-start
technology which
eliminates inrush
current at start-
up. The motors will
reliably start at any
speed setting.
Overload protection – If the motor becomes
overloaded, it will automatically reduce its speed until it
is no longer overloaded. This means that the motor will
never operate in the “service factor” which is possible
with many AC motors.
Locked rotor protection – If the motor ever encounters
a locked-rotor scenario, the motor will automatically
shut itself down. It will try to restart up to 3 times, and if
after the 3rd time the motor will still not rotate, the motor
will not attempt to start again until power is cycled.
Thermal protection – The motors have a one-shot
fuse thermal protector. This is meant to protect the
motor from a severe temperature rise. With the motor
controller’s ability to software limit the speed, the fuse
is used as a last resort to prevent a fire.
RPM measurement – The motors have a small shaft
extension on the end of the motor to measure motor
RPM with either a contact or optical tachometer.
Part Numbers Covered in this Section
309025 309026 310107 310306 310307
311352
These motors will accept a 0-10 VDC control signal for
speed control. From 0-1.9V, the motor will be off, and
will operate in the 2-10V range. 24 VAC/DC power is
also required for operation. The motor will consume
0.7VA at 24 VAC or 25mA at 24 VDC. A factory mounted
transformer is available to supply this voltage. See Fig. 1
The motor is pre-wired at the factory and cannot be
changed inside the motor. Connect single-phase power
at the voltage listed on the nameplate, along with the
0-10 VDC and 24V signal for speed control.
NOTE: The motor will not operate without the proper
control voltages.
Operation and Wiring
- 0-10V Input Only
Part Numbers Covered in this Section
309028 309029 310108 310475 310476
311353
Transformer Assembly
0-10 VDC External connection with factory mounted transformer
Fig. 1
®

3
Vari-Green Motor
These motors have both a potentiometer dial on the
motor for speed adjustment AND have the ability to
accept a 0-10 VDC signal for remote speed control.
NOTE: The presence or absence of the 24V power
determines whether the motor uses the dial or the
0-10VDC signal for speed reference.
There is a 4 second delay between the application of
power and the motor starting.
The motor is pre-wired at the factory and cannot be
changed inside the motor. Connect single-phase power
at the voltage listed on the nameplate. If remote control
is desired, connect the 0-10 VDC and 24V signal for
remote speed control.
Dial on motor – A small screwdriver can be used to
make the speed adjustment. To increase the speed,
rotate the dial clockwise. To decrease the speed, rotate
the dial counter clockwise. There is no need to connect
the control wires.
0-10 VDC signal – The dial on the motor must be
rotated fully clockwise to achieve the full speed range.
If this is not done, the dial will act as a maximum
speed limiter.
From 0-1.9V, the motor will be off, and will operate in
the 2-10V range. 24 VAC/DC power is also required for
operation. The motor will consume 0.7VA at 24 VAC
or 25mA at 24 VDC. A factory mounted transformer is
available to supply this voltage. See Fig. 1
A low voltage wiring harness is needed to supply the
0-10V signal to the motor. This harness is available from
the factory if conversion is necessary.
Part Numbers Covered in this Section
310359 311731 311377 311388 311812
312359 312360 312361 312362 312619
Operation and Wiring
- Potentiometer Dial and 0-10V Input
Type Use with Motor 18 in. long 36 in. long
3-pin 311731, 310359 384431 384432
9-pin
312359, 311377,
311812, 311388,
312360, 312361,
312362, 312619
384840 384805
0-10V Analog input connection
Red + 0-10 VDC
White Common*
Black +24 VAC/DC
*Common is shared between both 24V power
and 0-10V signal.
The impedance of 0-10V circuit is 12KΩ
Factory Mounted Transformer (Fig. 1)
A factory mounted transformer is available to
supply 24 VDC power to the motor when the
0-10V signal is by others. This transformer has
the capability to power a remote device if desired.
The power available to a remote device is 400mA
at 24 VDC. If the remote device is powered by
a different source, connect the analog output to
the 0-10V and COM terminals of the transformer.
This will pass the signal through to the motor.
WARNING
Do not connect an external 24V transformer to the
control terminal labeled 24V. If the external device
providing the 0-10V signal is powered elsewhere,
this terminal can remain unused.
Troubleshooting
Motor does not operate
1. Check all wiring connections to ensure they are
correct and secure.
2. Verify that all voltages are present at the motor,
including 24V and 0-10 VDC, if applicable.
3. Make sure that the fan wheel will rotate freely and
there are no foreign objects in the wheel. If fan wheel
does not rotate freely, disconnect power from the
motor and adjust the wheel or housing until the
wheel can freely rotate. Apply power and the motor
should restart.
4. If motor has both the dial on the motor and 0-10VDC
control option, control wiring issues can be tested
by disconnecting the control wires from the motor.
The motor should then operate using the dial on the
motor for speed control.
Motor will not reach maximum speed
1. Make sure dial is rotated full clockwise, if applicable.
2. Make sure motor is receiving 10 VDC, if applicable.
3. There are some motor/fan combinations
where the motor may not reach nameplate
RPM. See Max RPM table on page 10 for the
maximum motor speed for your application.
NOTE
The 9-pin connector on the motor contains 6 wires.
The red, black and white wires are used for the
external control signal and the other three are used for
factory initialization and programing.
®

4Vari-Green Motor
Wiring
1. All high and low voltage wiring connections are made
inside the motor control box at the factory. Normally,
there is no reason to enter the control box of the
motor. If there is a need to enter the control box,
disconnect power and wait at least five minutes to
allow the capacitors to discharge.
2. The motors are factory wired for the ordered voltage.
If the factory wired voltage does not match the
desired voltage, the voltage can be changed, with
exception of the 2HP motor (310420), which is
208-240V only.
115V: Connect 115 VAC to L1, connect Neutral to N.
The L2 terminal remains empty. Connect ground to
grounding stud.
208-240V - Connect Line voltage to L1 and L2. The
N terminal remains empty. Connect the ground to the
grounding stud.
Part Numbers Covered in this Section
310420 311156
Features
Speed control -
These motors can
be controlled by
either a dial on the
motor or a 0-10 VDC
signal for remote control.
Soft start – All motors feature soft-start technology
which eliminates inrush current at start-up. The motors
will reliably start at any speed setting. There will be up
to a 30 second delay between the application of power
and the motor starting.
Overload protection – If the motor becomes
overloaded, it will automatically shut itself down. The
maximum programed motor speeds have been selected
to prevent this from happening in normal operation.
Locked rotor protection – If the motor encounters a
locked-rotor scenario, it will automatically shut itself
down. It will try to restart up to 3 times, and if after the
3rd time the motor will still not rotate, the motor will not
attempt to start again until power is cycled.
Thermal protection – The motors have an automatic
reset thermal protector. This is meant to protect the
motor from a severe temperature rise.
RPM measurement – The motor RPM can be
measured by removing the cooling fan cover and using
a contact or optical tachometer. Be sure to replace the
cooling fan cover when finished.
Reversible rotation – The motor direction has been
pre-set at the factory for the rotation of the fan but can
be reversed if necessary.
Operation and Wiring
These motors can be controlled by either a dial on the
motor or a 0-10 VDC signal for remote control. The
motor will be supplied from the factory with the correct
accessory depending on what was ordered.
Dial on Motor - Turn the dial with your fingers to adjust.
To increase the speed, rotate the dial clockwise. To
decrease the speed, rotate the dial counter clockwise.
Turning the dial full CCW will turn the motor off.
0-10 VDC Signal - From 0-1.9V, the motor will be off,
and will operate in the 2-10V range. This motor does not
require 24V power for operation.
115V Connection inside control box
208-240V Connection inside control box
0-10V Analog input connection
Red + 0-10 VDC
White Ground
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5
Vari-Green Motor
Dial on motor - the dial
is factory-wired into the
low voltage terminal block
inside the control box.
The wires are connected
as shown.
0-10 VDC Signal - a two-wire
pigtail is factory-wired into the
low voltage terminal block.
The wires are connected
as shown.
If the motor needs to be tested before the 0-10 VDC
signal is available, a jumper can be placed between
terminals 1 and 2. This will force the motor to run at
full speed.
Motor Rotation
To reverse the rotation of the motor, swap any two of
the red, black and blue wires connecting the control
board to the motor at terminals T1, T2 and T3. Note
that motor warranty is void if motor is rotating in the
wrong direction. See fan instruction manual for correct
rotation direction.
Troubleshooting
These motors have a diagnostic red LED on the circuit
board inside the control box, or on the exterior of the
control box, that will be solid (not flashing) when power
is applied to the motor and the motor is operating
normally. The LED may be solid even if the motor is not
spinning, such as when power is applied but the motor
may be commanded to be off with a 0-1.9V VDC signal.
1. If external LED is not present, to view the status of
the LED the control box cover must be removed
while power is applied to the motor. If the control
box cover is removed while power is applied,
extreme care must be taken not to touch any of the
components inside the box.
a. If a fault occurs, the LED will blink a specific
number of times to identify the fault that has
occurred. The fault indications are as follows:
3. When the LED is blinking, it will consecutively blink
from 2 to 9 times, followed by a pause, and repeat
the blink sequence. It is best to count the number
of flashes 2 or 3 times to ensure accuracy.
4. Under most fault conditions the motor will
automatically restart. If a motor overload fault occurs
more then 10 times in one hour, the motor will shut
down and require a power cycle to reset.
5. If the fault persists, consult the factory.
Motor does not operate
1. Verify the motor is wired for the correct voltage.
2. Verify that the dial on the motor is properly
connected to the control board - or - verify that
the 0-10 VDC wires are properly connected to the
control board.
3. Verify that the Status LED is solid red.
4. Verify that a jumper is in place between terminals
9 and 10. The motor will not run without this jumper
in place.
5. Verify that the two yellow wires coming from the
motor are in place on terminals 5 and 6.
Dial on motor connection inside control box
0-10 VDC Signal connection inside control box
Rotation selection wires inside control box
T3
Number of Blinks Indicated Fault
2 Overcurrent
3 Overvoltage
4 Undervoltage
5 Communication Error
6 Sync Loss
7 Spin Fault
8 Motor overload
9 Motor Over Temperature
RED
WHITE
BLACK
YELLOW
YELLOW
RED
WHITE
YELLOW
YELLOW
®

6Vari-Green Motor
Part Numbers Covered in this Section
310175 310176 310177 310178
Features
Speed control -
These motors can
be controlled by
either the dial on the
motor or a 0-10 VDC signal for remote control.
Soft start – All motors feature soft-start technology
which eliminates inrush current at start-up. The motors
will reliably start at any speed setting. There will be a 4
second delay between the application of power and the
motor starting.
Overload protection – If the motor becomes
overloaded, it will automatically reduce its speed until
it is no longer overloaded. This prevents the motor
from operating in the "service factor" should the motor
be misapplied.
Locked rotor protection – If the motor ever encounters
a locked-rotor scenario, the motor will automatically
shut itself down. It will try to restart up to 3 times, and if
after the 3rd time the motor will still not rotate, the motor
will not attempt to start again until power is cycled.
Thermal protection – The motors have electronic
thermal protection. If the motor temperature exceeds
its limits, it will slow itself down until the temperatures
have dropped.
Operation and Wiring
These motors can be controlled by either the dial on
the motor or a 0-10 VDC signal for remote control.
The motor will be supplied from the factory with the
correct accessory depending on what control option
was ordered.
Dial on Motor - Turn the dial with your fingers to adjust.
To increase the speed, rotate the dial clockwise. To
decrease the speed, rotate the dial counter-clockwise.
Turning the dial full CCW will turn the motor off. A 16-pin
connector with two jumper wires must be installed for
the dial to function. (p/n 384962) See image below.
0-10 VDC Signal - From 0-1.9V, the motor will be off,
and will operate within the 2-10V range. This motor
does not require 24V power for operation. For 0-10V
operation, a 16-pin connector with two wires connected
to pins 8 and 16 is required. (18 in. #384822 •
36 in. #384821)
Wiring
A power cord with a 5-pin connector is required and
is shipped with the motor. A different cord assembly is
needed depending on the desired voltage:
115V - 18 in. #384824 • 36 in. #384823
208-230V - 18 in. #384826 • 36 in. #384825


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7
Vari-Green Motor
Controls: Operation, Wiring and Troubleshooting
Remote Dial and 2-Speed Control
Remote Dial
Installation Overview: The remote dial is provided with
the fan, shipped loose for remote installation. It also
includes a factory mounted 24 VDC transformer.
1. Disconnect power to the fan.
2. Identify where the remote dial will be mounted.
3. Mount a standard single-gang 2x4 junction box.
4. Run a 3-wire control cable from the remote dial to
the fan motor compartment. The maximum distance
from the fan to the remote dial is 100 feet. If a greater
distance is required, signal loss may occur and cause
the fan to operate erratically.
5. Connect control cable to transformer mounted inside
fan motor compartment. Connect control cable to
remote dial.
6. Secure remote dial to 2x4 junction box.
CAUTION
Even though the motor may not be operating,
high voltage power may still be present at the motor.
Make sure to disconnect power to the fan before
servicing.
Troubleshooting - Remote Dial
Remote Dial does not adjust motor RPM
1. Check voltage to ensure the motor and transformer
are receiving the correct line voltage.
2. Check voltage at the remote dial. 24 VDC should
be present across the 24V and COM terminals.
0-10VDC should be present across the 0-10V and
COM terminals.
3. Verify all of the connections at the transformer and
make certain that they are secure.
Terminals Desired Voltage
24V-COM 24 VDC Nominal
0-10V-COM 0-10 VDC
(varies with dial position)
Other Vari-Green®controls, such as the Constant Pressure and Air Quality families of controls, have their own
manual that ship with the controller. They can also be found on Greenheck.com. See table on page 9 for document
numbers.
Remote Dial Assembly
®

8Vari-Green Motor
Controls Maximum Motor Quantity
Remote Dial 4
2 Speed 6
Constant Pressure 4
Temperature/Humidity 2
VOC 2
Multiple motors on one control
See the table below for the recommended number of
motors to be driven from one controller. Note that the
controllers do not have the ability to distinguish between
more than one motor, therefore all motors will receive
the same control voltage.
Two Speed
Installation Overview: The two speed control is factory
mounted to the fan and may be set to provide any
two speeds the application requires. It also includes a
24 VAC transformer which has a dual voltage primary
(115/230V), selectable via a switch on the housing
near the power cable. The voltage will be factory set to
match the motor voltage.
1. A green LED will be illuminated when the 2-speed
control is powered.
2. There are two methods of toggling between speed A
and speed B:
a. Dry contact input - this utilizes an external
switching device such as a relay or SPDT switch
to toggle between the two speeds.
• Connect terminal “A” to “COM” for speed A.
• Connect terminal “B” to “COM” for speed B.
If no contact is made between either terminal the
motor will be off.
b. AC Digital input - this input allows an AC voltage
signal to be fed directly into the 2-speed control
to change speeds.
• Send 115-230V AC to L1 OR L2 for speed B.
• Send 115-230V AC to L1 AND L2 for speed A.
If no voltage is applied to either terminal, the
motor will be off.
c. DO NOT CONNECT BOTH DRY CONTACT AND
DIGITAL INPUTS SIMULTANEOUSLY.
3. To test fan operation before the external control
devices are installed, a jumper wire can be
connected between the COM and A or B terminal on
the dry contact input for fan operation.
Troubleshooting - Two Speed
1. Check all wiring connections to ensure they are
correct and secure.
2. Verify AC line voltage is present at the motor and
2-speed control.
3. Verify 24V AC is present at the 24V and COM
terminals of the "Motor" terminal block.
4. Measure DC voltage between the 0-10V and COM
terminals of the "Motor" terminal block. This voltage
should match the dial position of the active dial.
a. If using dry contact input - ensure contact closure
is connecting the proper terminals.
b. If using AC digital input - disconnect connector
from 2-speed control and measure voltage
between L1 and Neutral or L2 and Neutral.
Two Speed Assembly
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9
Vari-Green Motor
Maintenance
Vari-Green®motors use brushless technology with
sealed bearings. No routine maintenance is required
other than keeping any debris from accumulating on the
motor and controls.
Other Vari-Green®Control
Instruction Manuals
Description Document Number
Indoor Air Quality - VOC 475407
Indoor Air Quality -
Temperature/Humidity 475573
Constant Pressure Control 474766
Notes:
®

10 Vari-Green Motor
Maximum RPM Table
This table will show the available motor and fan
combinations with the correlating maximum
motor RPM for each combination.
G Max RPM Motor HP
60-75 1725 1/6
80-95 1725 1/6
97-99 1725 1/4
103 1725 1/4
103HP 1725 1/4
2500 1/2
123 1200 1/4
1725 1/2
133
1150 1/4
1550 1/2
1725 3/4
143
900 1/4
1200 1/2
1300 3/4
1725 1
143HP
1500 1/4
1725 1/2
2200 3/4
163
750 3/4
1200 1
1725 2
183
900 3/4
1000 1
1400 2
CUE/CW Max RPM Motor HP
60-75 1725 1/6
80-95 1725 1/6
99 1725 1/4
101 1725 1/4
101HP 1725 1/4
2500 1/2
121 1400 1/4
1725 1/2
131
1200 1/4
1450 1/2
1725 3/4
141
1000 1/4
1300 1/2
1550 3/4
1725 1
141HP
1450 1/4
1725 1/2
2200 3/4
161
1000 1/2
1200 3/4
1300 1
1725 2
161HP
1300 1/2
1650 3/4
1725 1
180
875 3/4
1000 1
1400 2
SE1/SS1 Max RPM Motor HP
8-440 1725 1/6
10-440 1725 1/6
12-426 1725 1/4
12-432 1725 1/4
12-436 1725 1/4
14-432 1725 1/4
14-436 1725 1/2
14-440 1725 1/2
16-421 1725 1/2
16-426 1725 1/2
16-428 1725 3/4
16-436 1725 3/4
18-424 1725 3/4
18-429 1725 3/4
20-420 1725 1
SQ Max RPM Motor HP
60-75 1725 1/6
80-95 1725 1/6
100 1725 1/4
120 1725 1/2
130 1725 3/4
140 1500 3/4
1725 1
160
1140 3/4
1300 1
1725 2
SFD Max RPM Motor HP
6 1725 1/4
7.5 1725 1/2
LD/LDP Max RPM Motor HP
80-95 1725 1/6
100 1725 1/4
120 1725 1/2
SWD Max RPM Motor HP
71725 1/4
2500 1/2
81725 1/4
2500 1/2
10 1725 1/4
2200 3/4
13
1200 1/4
1550 1/2
1725 3/4
15
1150 1/2
1400 3/4
1725 1
16
900 3/4
1300 2
1725 2
18
850 3/4
950 1
1300 2
®

11
Vari-Green Motor
®

12 473681 • Vari-Green Motor, Rev. 5, July 2013 Copyright 2013 © Greenheck Fan Corporation
®
Phone: [phone] • Fax: [phone] • E-mail: [email protected] • Website: www.greenheck.com
As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications
without notice.
Specific Greenheck product warranties can be located on greenheck.com within the product area tabs and
listed in the Library under Warranties.
Our Commitment
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.