Greenheck Vari-Green® Drive
Installation, Operation and Maintenance Manual
Document 481200
VGD-100 / 100+
General Information
The Vari-Green Drive (VGD) is a factory-mounted and wired variable frequency drive. It is programmed at the factory to match the characteristics of the fan and motor on which it is installed.
Safety Instructions
As with all electrical products, read the manual thoroughly before operating. Only qualified personnel should perform maintenance and installation. Do not disassemble or repair the unit. Death or injury due to electrical shock may result.
To prevent injury and property damage, follow instructions during installation and operation of the VGD. Incorrect operation of the VGD may cause harm and/or damage.
This manual should be placed in a location where it can be accessed by the users of this product and by those that are responsible for its maintenance.
WARNING
- Do not remove VGD cover for wiring or periodic inspections while power is applied or the unit is in operation. Electric shock may occur from the exposed terminals and bus bars.
- Wait at least 1 minute after disconnecting the input power and also verify all LEDs including the Power and Charge LEDs are off before performing any wiring tasks and/or periodic inspections on the VGD.
- Operate VGD and control devices with dry hands.
- Do not use VGD if power or motor cable is damaged.
CAUTION
- Disconnect the input power if VGD has been damaged. Failure to do so may result in fire and secondary damage or accidents.
- Do not touch VGD immediately after shutting down or disconnecting it. It can remain hot for a few minutes. Bodily injuries such as skin-burn or damage may occur.
- Do not apply power to a damaged VGD or to a VGD with missing parts.
- Do not allow lint, paper, wood chips, dust, metallic chips or other foreign material into the drive as it may cause fire or accident.
Features
Models 100 and 100+
- Analog input speed control options: On-board dial, 0-10VDC signal, 4-20mA signal
- Compatible with Vari-Green controls
- Power, run, fault LEDs
- 24VDC @ 0.5A damper actuator power output
- 24VDC @ 50mA control power output
- Motor protection: Thermal overload, over voltage, under voltage, input phase loss, over current, overheat, short circuit, hardware error, cooling fan failure
- R3 Filtering™: Helps meet IEEE 519 without an external line reactor or filter
- Bluetooth/smart phone interface
Additional Features for Model 100+
- Relay outputs: (2) programmable relay outputs for run, fault, proof of run (configurable for normally open and normally closed)
- Inputs: Can be configured through companion app for run, FWD, stop, fireman's override, speed A, speed B, speed AB, damper limit switch, shut down, and fault reset. Includes (2) configurable wet inputs (12-250 VAC/VDC, 8mA maximum) and (2) configurable dry inputs (programmable to N.O. or N.C.).
- RS-485 communications: Modbus, BACnet
- On-board PID control (configurable through companion app)
- Optional pressure transducer
Overview Diagram
The diagram shows the VGD with labeled components including Power Input, Control Wiring Terminal Block, Motor Output, RS-485 Terminal, Analog Input, Dip Switch, Optional Pressure Transducer, and Programmable Inputs/Outputs.
Startup Procedure
Power Wiring
The Vari-Green Drive power input and output connections are pre-wired at the factory. Refer to local electrical codes for branch circuit protection and proper wiring size and type. Power input terminals are marked R, S, T. Power output terminals (to motor) are marked U, V, W. Note: For specific part numbers, the VGD has internal fuse protection and does not require a fused disconnect.
Control Wiring for Models 100 and 100+
| Terminal | Description | Rating | Notes |
|---|---|---|---|
| Q1, Q2 | Relay Output Split O | 125VAC-0.5A / 250VAC-0.25A / 30VDC-2.0A / 125VDC-0.24A / 220VDC-0.24A | Can be configured to "N.O." (default) or "N.C." |
| V1, V2 | Voltage Input 1 | 12-250V AC/DC / 8mA Max draw at 10V min., Off at 3V | Can be configured to "Active High" (default) or "Active Low". |
| V3, V4 | Voltage Input 2 | Max 52kOhm input impedance | Functions: enable, limit switch, fireman's override, speed A, speed B, shutdown |
| D1 | Dry Input 1 | 24VDC when open / short to SG to activate | |
| D2 | Dry Input 2 | ||
| SG | Input Common |
Control Wiring for Model 100+
| Terminal | Description | Rating | Notes |
|---|---|---|---|
| A+ | Damper Output | 24 VDC / 0.5A max | Programmable activation modes |
| A- | |||
| 24 | 24 VDC Output | 24 VDC / 50mA max | |
| Al | Analog Input | 0-24V / 0-10V / 4-20mA | Voltage or current input configurable via analog dip switches 1 & 2 |
| SG | |||
| RS-485 Communications | N/A | Modbus, BACnet |
Speed Control Option Wiring Connections
| Speed Control Option | Wiring Connections (VGD) | Ex. Device | Analog Dip Switch Settings | Notes |
|---|---|---|---|---|
| On-Board Dial | 24, Al, SG | RED, WHITE, BLACK | 1: ON, 2: OFF | On-board Dial Part Number 384588 |
| 0-10VDC Signal | 24, Al, SG | 0-10VDC, GROUND | 1: OFF, 2: OFF | 2-10V Active Range |
| 4-20mA Signal | 24, Al, SG | 4-20mA, GROUND | 1: ON, 2: ON | 4-20mA Active Range |
| Other Vari-Green controls | 24, Al, SG | 24V POWER, 0-10V SIGNAL, COMMON/GROUND | 1: OFF, 2: OFF | Refer to control manual wiring diagram for connections to control |
First Application of Power
Warning: Ensure fan is properly installed and all parts can freely rotate. Loose tools, parts and clothing must be secured before starting fan. Stay clear of rotating shafts, belts and pulleys.
- Apply the proper input voltage to the VGD after all wiring connections have been made.
- Provide the drive with a run command (rotate dial clockwise or provide a control signal greater than 2VDC or 4mA).
- Check rotation of fan to ensure it matches the rotation direction label on the fan. The rotation should be factory set. If incorrect, disconnect and lock-out power, then swap any two of the three leads between the VGD and motor. Power output terminals are marked U, V, W. Note: Swapping leads on the input of the VGD will have no effect on rotation.
- Slowly ramp fan to full speed and make sure no faults are present and the fan is operating smoothly.
Operation Notes
- LED Status: There are three LEDs on the front cover: Power (green when power is applied), Run (solid green when running, blinking green if run command present but no motor current), and Fault (flashing red when a fault has occurred).
- On-Board Dial: Rotate clockwise to increase fan speed, counterclockwise to decrease. Full counterclockwise stops the fan.
- 0-10V Input: Fan operates from 2-10VDC (2V minimum, 10V maximum). 0-1.9V turns the fan off.
- 4-20mA Input: Fan operates between 4-20mA (4mA minimum, 20mA maximum). 0-3.9mA turns the fan off.
- Vari-Green Controls: Programmed speeds enacted through inputs (model 100+ only). Refer to companion app section.
- Belt Drive Fans: Factory belt and pulley sizes are selected for ordered fan RPM. Motor HP is sized for 60 Hz operation. Note: Design fan RPM may be less than maximum fan RPM. Warning: Replacing belts/pulleys to increase fan speed may overload the motor/VGD and cause a fault. Never exceed maximum fan RPM.
Troubleshooting
When a fault is present, the VGD turns off its motor output and flashes the fault LED. Each fault is associated with a certain number of blinks (0.5 seconds on, 2 seconds off).
| Number of LED Blinks | LED Blink Fault | Fault # | Description | Run LED | Fault LED |
|---|---|---|---|---|---|
| VGD is off and there are no faults | OFF | OFF | |||
| VGD is running and there are no faults | ON | OFF | |||
| Run command present with no proof of flow | Blinking | OFF | |||
| VGD is off with Fault | OFF | Fault blink sequence | |||
| 1 | Thermal Overload | 1 | |||
| 2 | Motor Overcurrent | 2 | |||
| 3 | Overcurrent | 3 | |||
| 5 | Output Phase Open | 5 | |||
| 9 | PM Motor Sync Fault | 9 | |||
| 2 | Over Voltage | 6 | Over Voltage | ||
| 3 | VGD Overheat | 10 | VGD Overheat | ||
| 7 | Under Voltage | 4 | Under Voltage | ||
| 8 | Input Phase Open | 8 | Input Phase Open | ||
| 5 | VGD Short Circuit | 4 | VGD Short Circuit | ||
| 6 | Cooling Fan Failure | 12 | Cooling Fan Failure | ||
| 13 | Limit Switch Failed to Close | ||||
| 7 | Damper | 14 | Damper Power Over Current | ||
| 8 | HW Fault | 16 | Hardware Failure | ||
| 9 | Comms Loss | 11 | Lost Communication |
Fault Details
| Fault | Cause | Remedy |
|---|---|---|
| Thermal Overload | If current is within the inverse trip curve for motor rated current class of 10 and service factor of 1.15. | Make sure fan speed is not over maximum for motor size. |
| Overcurrent | If output current is continuously above the trip current threshold multiplied by the rated current (per VGD UL label) for a time greater than the trip time. | Check if rotor is locked and/or mechanical obstructions to motor/fan. Check motor wiring and windings. Conduct a mechanical inspection on the system. Frequent starting with this fault may damage the VGD power components. |
| VFD Short Circuit | If short circuit is detected on the output terminals of the VGD. | Check output wiring. Check motor wiring. |
| Output Phase Open | If the output phase current of one phase is less than or equal to the average of the two remaining phases by the specified percentage. | Ensure motor is properly connected to VGD. |
| Over Voltage | If DC bus voltage is greater than or equal to 800VDC for 400V model and 400VDC for the 240V model. | Check line voltage and call utility company. |
| Under Voltage | If DC bus voltage is less than internal setting (corresponds to 90% of lowest rated input voltage for 2 seconds). | Check line voltage. Check fuses. |
| Input Phase Open | If any one of the input phases is disconnected. | Check input wiring. Check input power. Check fuses. |
General Troubleshooting
| Symptom | Possible Causes | Possible Solution |
|---|---|---|
| VGD does not operate fan | No control input signal | Ensure proper voltage/current is measured on the Al terminal. |
| "Analog" dip switch settings incorrect | Verify dip switch matches proper control signal (pg. 3). | |
| Speed range is incorrect | "Analog" dip switch settings incorrect | Verify dip switch matches proper control signal (pg. 3). |
| Cooling fan failure fault | Cooling fan unplugged/not functioning | Check cooling fan. |
Maintenance
The Vari-Green Drive (VGD) is an industrial electronic product with advanced semiconductor components. Its operation depends on installation and operation conditions such as temperature, humidity, vibration, dust, etc. Routine inspections of all operating VGDs are recommended in addition to the maintenance recommended in the fan's instruction manual.
Precautions
- Remove input power while performing maintenance procedures.
- Use a true RMS multimeter to ensure voltage is not present at the output terminals. Other types of voltmeters cannot read high frequency pulse width modulation (PWM) output voltage correctly.
Periodic Inspection
- Check for loose connections, bolts, nuts or rust buildup caused by surrounding conditions.
- Check for any discoloration or visual damage to the various connectors inside the VGD. Call Greenheck for support if any discolored or damaged connectors are found.
- Ensure heat sink fins underneath the VGD are free of obstructions and debris.
Companion App
The companion app for the VGD is available through the Apple App Store. A quick start guide is available for the companion app under the instruction manuals at: https://www.greenheck.com/vari-green/vari-green-drives.
The companion app features:
- Dashboard: Monitor fan performance on your mobile device. Switch VGD to ‘Hand’ mode for easy troubleshooting, testing, adjusting, and balancing.
- Set-up wizards: For different control modes including Dial on motor, 0-10V control, 4-20mA control, Remote dial/touch remote, Multi-speed, Constant pressure control, Constant air flow control, VOC, Temp/humidity control, On-board PID.
- Create start-up reports.
- Copy current configuration and settings to apply to other VGDs.
- View fault logs.
- View hardware status and update firmware.
- View documentation: Access to cut sheets, IOMs and quick start guides.
- Contact technical support: Use the "Call tech support" button to dial Greenheck Fan Corporation for troubleshooting, parts, information, etc. Use the "Email tech support" button to send VGD settings and fault log, as well as pictures, to the Greenheck Fan Corporation support center.
Specifications VGD Model 100
| Part Numbers | 385817 | 385818 | 386221 | 386222 | 386168 | 386169 | |
|---|---|---|---|---|---|---|---|
| Output Ratings | Voltage | 0-240 VAC | 0-480 VAC | 0-240 VAC | 0-480 VAC | 0 - 240 VAC | 0-480 VAC |
| Max motor FLA | 8.0A | 6.0A | 8.0A | 6.0A | 16.0A | 14.0A | |
| Frequency*: 15 - 240 Hz | Yes | Yes | Yes | Yes | Yes | Yes | |
| Phase | 3 Φ | 3 Φ | 3 Φ | 3 Φ | 3 Φ | 3 Φ | |
| Voltage (+15%/-10%) | 200-240 VAC | 380-480 VAC | 200-240 VAC | 380-480 VAC | 200-240 VAC | 380 - 480 VAC | |
| Frequency: 50/60 Hz (±5%) | Yes | Yes | Yes | Yes | Yes | Yes | |
| Phase | 3 Φ | 3 Φ | 3 Φ | 3 Φ | 3 Φ | 3 Φ | |
| Efficiency, full load | ≥ 96% | ≥ 98% | ≥ 96% | ≥ 98% | ≥ 96% | ≥ 98% | |
| Power Factor | ≥ 0.9 | ≥ 0.85 | ≥ 0.9 | ≥ 0.85 | ≥ 0.9 | ≥ 0.85 | |
| % THD (meets IEEE 519) | 32.0 | 32.0 | 32.0 | 32.0 | 32.0 | 32.0 | |
| On Board Fuses | No | No | Yes | Yes | Yes | Yes | |
| Certifications Environment | Max Ambient Temperature | 40°C (104°F) | 40°C (104°F) | 40°C (104°F) | 40°C (104°F) | 40°C (104°F) | 40°C (104°F) |
| Storage Temperature | -30 to 65°C (-22°F ~ 149°F) | -30 to 65°C (-22°F ~ 149°F) | -30 to 65°C (-22°F ~ 149°F) | -30 to 65°C (-22°F ~ 149°F) | -30 to 65°C (-22°F ~ 149°F) | -30 to 65°C (-22°F ~ 149°F) | |
| Relative Humidity (Non-condensing) | Up to 95% RH | Up to 95% RH | Up to 95% RH | Up to 95% RH | Up to 95% RH | Up to 95% RH | |
| Agency Approvals UL Listed E223975 | Yes | Yes | Yes | Yes | Yes | Yes | |
| Enclosure Rating | Type 4/IP66 | Type 4/IP66 | Type 4/IP66 | Type 4/IP66 | Type 4/IP66 | Type 4/IP66 |
*Actual frequency range will vary.
Specifications VGD Model 100+
| Part Numbers | 385819 | 385820 | 386422 | 386423 | |
|---|---|---|---|---|---|
| Output Ratings | Voltage | 0-240 VAC | 0-480 VAC | 0-240 VAC | 0 - 480 VAC |
| Max motor FLA | 8.0A | 6.0A | 16.0A | 14.0A | |
| Frequency*: 15 - 240 Hz | Yes | Yes | Yes | Yes | |
| Phase | 3 Φ | 3 Φ | 3 Φ | 3 Φ | |
| Voltage (+15%/-10%) | 200-240 VAC | 380-480 VAC | 200-240 VAC | 380-480 VAC | |
| Frequency: 50/60 Hz (±5%) | Yes | Yes | Yes | Yes | |
| Phase | 3 Φ | 3 Φ | 3 Φ | 3 Φ | |
| Efficiency, full load | ≥ 96% | ≥ 98% | ≥ 96% | ≥ 98% | |
| Power Factor | ≥ 0.9 | ≥ 0.85 | ≥ 0.9 | ≥ 0.85 | |
| % THD (meets IEEE 519) | 32.0 | 32.0 | 32.0 | 32.0 | |
| On Board Fuse Protection | Yes | Yes | Yes | Yes | |
| Certifications Environment | Max Ambient Temperature | 40°C (104°F) | 40°C (104°F) | 40°C (104°F) | 40°C (104°F) |
| Storage Temperature | -30 to 65°C (-22°F ~ 149°F) | -30 to 65°C (-22°F ~ 149°F) | -30 to 65°C (-22°F ~ 149°F) | -30 to 65°C (-22°F ~ 149°F) | |
| Relative Humidity (Non-condensing) | Up to 95% RH | Up to 95% RH | Up to 95% RH | Up to 95% RH | |
| Agency Approvals UL Listed E223975 to 61800-5-1 | Yes | Yes | Yes | Yes | |
| Enclosure Rating | Type 4/IP66 | Type 4/IP66 | Type 4/IP66 | Type 4/IP66 |
*Actual frequency range will vary.
RS-485 Communication - Model 100+
The Vari-Green Drive (VGD) can be controlled and monitored through the Modbus RTU and BACnet MS/TP protocol over an RS-485 connection.
MODBUS RTU Communications
Modbus follows a client-server model. Server devices perform data read/write requests from a client device (e.g., PLC, building management system). Assignable addresses range from 1 to 247. The VGD communicates data using 16-bit holding registers. If configured for remote communications, the drive can be commanded to start, stop, run at a specified output frequency, target a setpoint in PID control, and reset faults. For a complete address list, contact Greenheck Fan Corporation support at 1-800-984-8713.
View Information Parameter Group
| Modbus Address | Read/Write | Full Parameter Name | Parameter Setting Range |
|---|---|---|---|
| 527 | R/W | Run/Stop | 0 - Stop 1 - Run |
| 601 | R/W | VFD Output Frequency | 0.00 to 240.00 [Hz] |
| 611 | R | Output Status | 0 - VFD Off 1 - Accelerate 2 - Decelerate 3 - Steady 4 - Speed search 5 - Flying start 6 - DC Output 7 - Preheat 8 - DC trip prevention 9 - Stall prevention |
| 612 | R | System Status | 0 - VFD stop 1 - VFD run 2 - VFD disabled 3 - VFD fault 4 - VFD shutdown 5 - VFD Fireman's override 6 - VFD auto reset 8 - Power-on delay 12 - Signal loss 14 - PID run 15 - Open Damper |
| 613 | R | Fault | 0 - None 1 - Motor Overload (C) 2 - Motor Over Current (C) 3 - VFD Over Current (C) 4 - VFD Over Heat (C) 5 - VFD Short Circuit (C) 6 - Over Voltage (L) 7 - Under Voltage (L) 8 - Input Phase Open (L) 9 - Output Phase Open (L) 10 - No Motor (L) 11 - Incorrect Output Wiring 12 - Power Board Uncalibrated 13 - Ground Fault (L) 41 - Limit Switch (H) 42 - Damper Overload (L) 43 - Control Reserved 44 - No Flow (L) 45 - External Trip (M) 46 - Power Board Error (M) 47 - Control Board Error (M) 48 - VFD Cooling Fan (L) 49 - Power Board Comms Error (M) 51 - BMS Communications Loss (A) 52 - Analog Signal Loss 53 - Transducer Signal Loss (A) 54 - EEPROM Error 55 - Calibration CRC Failed 56 - Bluetooth Key CRC Failed 57 - Invalid Firmware 58 - Option board error |
| 623 | R | D1-SG Input | 0-Open 1-Closed |
| 624 | R | D2-SG Input | 0-Open 1-Closed |
| 625 | R | V1-V2 Input | 0 - De-energized 1 - Energized |
| 626 | R | V3-V4 Input | 0 - De-energized 1 - Energized |
| 627 | R | Q1-O Output | 0-Open 1-Closed |
| 651 | R | Q2-O Output | 0-Open 1-Closed |
BACnet MS/TP Communication
The VGD operates as an MS/TP master device and supports addressing for up to 128 master devices in a single MS/TP network. BACnet conveys control and monitoring data as BACnet objects. The VGD supports analog input, analog value, positive integer value, binary input, multi-state value, and character string object types. Read property and write property services interface to these objects. If the drive is configured for remote communications, it can be commanded to start, stop, run at a specified output frequency, target a setpoint in PID control, and reset faults.
Parameter Code Lists
Analog Value Object
| BACnet Object Instance | Read/Write | Full Parameter Name | Parameter Setting Range |
|---|---|---|---|
| 42 | R | VFD Output Frequency | 0.00 to 240.00 |
Binary Input Object
| BACnet Object Instance | Read/Write | Full Parameter Name | Parameter Setting Range |
|---|---|---|---|
| 0 | R | D1-SG Status | 0-Open 1-Closed |
| 1 | R | D2-SG Status | 0-Open 1-Closed |
| 2 | R | V1-V2 Status | 0 - De-energized 1 - Energized |
| 3 | R | V3-V4 Status | 0 - De-energized 1 - Energized |
| 6 | R | Q1-O Status | 0-Open 1-Closed |
| 7 | R | Q2-O Status | 0-Open 1-Closed |
Multi-State Object
| BACnet Object Instance | Read/Write | Full Parameter Name | Parameter Setting Range |
|---|---|---|---|
| 51 | R | Output Status | 0- VFD Off 1- Accelerate 2- Decelerate 3- Steady 4- Speed Search 5- Flying Start 6- DC Output 7- Preheat 8- DC Trip Prevention 9- Stall Prevention |
| 52 | R | System Status | 0- VFD stop 1- VFD run 2- VFD disabled 3- VFD fault 4- VFD shutdown 5- VFD fireman's override 6- VFD auto reset 8- Power-on delay 12- Signal loss 14- PID run 15- Open damper |
| 56 | R/W | Run/Stop | 0- Stop 1- Run |
| 57 | R/W | Reset Fault | 0- None 1- Reset |
| 62 | R | Fault | 0- None 1- Motor Overload (C) 2- Motor Over Current (C) 3- VFD Over Current (C) 4- VFD Over Heat (C) 5- VFD Short Circuit (C) 6- Over Voltage (L) 7- Under Voltage (L) 8- Input Phase Open (L) 9- Output Phase Open (L) 10- No Motor (L) 11- Incorrect Output Wiring 12- Power Board Uncalibrated 13- Ground Fault (L) 41- Limit Switch (H) 42- Damper Overload (L) 43- Control Reserved 44- No Flow (L) 45- External Trip (M) 46- Power Board Error (M) 47- Control Board Error (M) 48- VFD Cooling Fan (L) 49- Power Board Comms Error (M) 51- BMS Communications Loss (A) 52- Analog Signal Loss 53- Transducer Signal Loss (A) 54- EEPROM Error 55- Calibration CRC Failed 56- Bluetooth Key CRC Failed 57- Invalid Firmware 58- Option board error |
Our Commitment
As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications without notice. Product warranties can be found online at Greenheck.com, either on the specific product page or in the literature section of the website at Greenheck.com/Resources/Library/Literature.
Greenheck
Building Value in Air.
Phone: 715.359.6171 • Fax: 715.355.2399 • Parts: 800.355.5354 • E-mail: gfcinfo@greenheck.com • Website: www.greenheck.com
481200 Vari-Green Drive, Rev. 4, May 2019
Copyright 2019© Greenheck Fan Corporation
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