www.plymovent.com

EN User manual

OS-3 AUTOMATIC SYSTEM CONTROL

EN Control Box

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TABLE OF CONTENTS

TABLE OF CONTENTS ......................................................................................................1

General Precautions ........................................................................................................2

Preface .........................................................................................................................4

1 Introduction ..................................................................................................................4

1.1 IdentificationofTheProduct ............................................................................................41.2 General Description ........................................................................................................41.3 Product Combinations .....................................................................................................41.4 TechnicalSpecifications ...................................................................................................41.5 Ambient Conditions ........................................................................................................41.6 TransportofTheUnit ......................................................................................................4

2 Product Description ........................................................................................................5

2.1 Operation ......................................................................................................................5

3 Safety...........................................................................................................................5

4 Installation ....................................................................................................................6

4.1 Unpacking .....................................................................................................................64.2 Electric Connection .........................................................................................................64.3 PrimaryWiringProcedure ................................................................................................64.4 PrimaryWiringProcedures(ControlWiring) .......................................................................74.5 TransformerWiringProcedure ..........................................................................................74.6 PressureSwitchProcedure ...............................................................................................84.7 TemperatureSwitchProcedure .........................................................................................84.8 Wireless Control System Procedure ...................................................................................8

5 Maintenance ..................................................................................................................9

6 Troubleshooting .............................................................................................................9

7 Spare Parts ...................................................................................................................9

8 Electricaldiagram ...........................................................................................................9

9 Disposal ........................................................................................................................9

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GENERAL PRECAUTIONS

ATTENTIONAllowonlyqualifiedpersonnelfamiliarwithadjustablefrequencyACdrives,andassociatedmachinerytoplanorimplementtheinstallation,start-upandsubsequentmaintenanceofthesystem.Failuretocomplycanresultinpersonalinjuryand/orequipmentdamage.

ATTENTIONToavoidanelectricshockhazard,verifythatthevoltageonthebuscapacitorshasdischargedbeforeperforminganyworkontheelectricalcontrols,switchesand/ordrivesifapplicable.

ATTENTIONIncorrectly applied or installed electrical controls, switchesand/ordrivescanresultincomponentdamageorareductioninproductlife.Wiringorapplicationerrors,suchas,undersizingthemotor,incorrect or inadequate AC supply, or excessive ambienttemperaturescanresultinmalfunctionofthesystem.

ATTENTIONTheelectricalcontrols,switchesand/ordrivesmaycontainESD(ElectrostaticDischarge)sensitivepartsand assemblies. Static control precautions may be requiredwheninstalling,testing,servicingorrepairingthisassembly.Componentdamagecanresult if ESD control procedures are not followed.

IMPORTANT USER INFORMATIONReadthisdocumentinentiretybeforeyouinstall,configure,operate,ormaintainthisproduct.Usersarerequiredtofamiliarizethemselveswithinstallationandwiringinstructionsinaddition to requirements of all applicable codes, laws and standards.

Activitiesincludinginstallation,adjustments,puttingintoservice,use, assembly, disassembly, and maintenance are required to be carriedoutbysuitablytrainedpersonnelinaccordancewithapplicable code of practice.

Ifthisequipmentisusedinamannernotspecifiedbythemanufacturer,theprotectionprovidedbytheequipmentmaybeimpaired.

In no event will Plymovent be responsible or liable for indirect or consequentialdamagesresultingfromtheuseorapplicationofthisequipment.

Theexamplesanddiagramsinthismanualareincludedsolelyforillustrativepurposes.Becauseofthemanyvariablesandrequirementsassociatedwithanyparticulateinstallation,Plymovent cannot assume responsibility or liability for actual use basedontheexamplesanddiagrams.

NopatentliabilityisassumedbyPlymoventwithrespecttouseofinformation,circuits,equipment,orsoftwarethatmaybedescribedinthismanual.Throughoutthismanual,whennecessary,notesmaybeusedtomakeyouawareofsafetyconsiderations.

Theoperationofexhaustextractionsystemscanbeaffectedbyvariousfactorsincludingbutnotlimitedtoproperdesignofthe

system,operatingprocedures,serviceandmaintenance.Fumeexhaustexposurelevelsshouldbecheckeduponinstallationandperiodicallythereaftertoensurethattheyfallwithinapplicableregulationsandexposurelimitvalues.

Plymoventsystemsaremadecodecompliant,pleaseensurethesystemisproperlydesigned,operated,servicedandmaintained.

WARNING!Identifiesinformationaboutpracticesorcircumstancesthatcancauseanexplosioninahazardousenvironment,whichmayleadtopersonalinjury,death,propertydamage,oreconomicloss.

ATTENTIONIdentifiesinformationaboutpracticesorcircumstancesthatcanleadtopersonalinjuryordeath,propertydamage,oreconomicloss.Attentionshelpyouidentifyahazard,avoidahazard,andrecognizetheconsequent.

IMPORTANTIdentifiesinformationthatiscriticalforsuccessfulapplicationandunderstandingoftheproduct.

SHOCK HAZARDLabelsmaybeonoutsideorinsideoftheequipment,forexamplecontrolbox,toalertpeoplethatdangerousvoltagemaybepresent.

ARC FLASH HAZARDLabelsmaybeonoutsideorinsideoftheequipment,for example control box, to alert people to potential ArcFlash.ArcFlashwillcausesevereinjuryordeath.WearproperPersonalProtectionEquipment(PPE).FollowALLregulatoryrequirementsforsafeworkpracticesandforPersonalProtectiveEquipment(PPE).

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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EN - ORIGINAL INSTRUCTIONAllrightsreserved.Theinformationgiveninthisdocumenthasbeencollectedforthegeneralconvenienceofourclients.Ithasbeenbasedongeneraldatapertainingtoconstructionmaterialpropertiesandworkingmethodsknowntousatthetimeofissueofthedocumentandisthereforesubjectatanytimetochangeoramendment,andtherighttochangeoramendisherebyexpresslyreserved.Changesmaybemadewithorwithoutnotification,itistheusersresponsibilitytoensuretheyhaveattainedthemostrecentcopyofthisdocumentfortheirfiles.Theinstructionsinthispublicationonlyserveasaguidelineforinstallation,use,maintenanceandrepairoftheproductmentionedonthecoverpageofthisdocument.Thispublicationistobeusedforthestandardmodeloftheproductofthetypegivenonthecoverpage.Thusthemanufacturercannotbeheldresponsibleforanydamageresultingfromtheapplicationofthispublicationtotheversionactuallydeliveredtoyou.Thispublicationhasbeenwrittenwithgreatcare.However,themanufacturercannotbeheldresponsible,eitherforanyerrorsoccurringinthispublicationorfortheirconsequences.

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PREFACE

Using this manualThismanualisintendedtobeusedasaworkofreferenceforprofessional,welltrainedandauthorizeduserstobeabletosafelyinstall,use,maintainandrepairtheproductmentionedonthecoverofthisdocument.Thisusermanualshouldalwaysbekeptwiththeproduct,aswellasaduplicatecopybekeptbythefiredepartmentorcityservicedepartmentafterinstallation.

Pictograms and symbolsThefollowingpictogramsandsymbolsareusedinthismanual:

ATTENTIONAremarkwithadditionalinformationfortheuser.Aremarkbringspossibleproblemstotheuser’sattention.CAUTION!Procedures,ifnotcarriedoutwiththenecessarycaution,coulddamagetheproduct,theworkshoportheenvironment.WARNING!Procedureswhich,ifnotcarriedoutwiththenecessarycaution,maydamagetheproductand/orcauseseriouspersonalinjury.CAUTION!Riskofelectricshock.

WARNING!Firehazard!Importantwarningtopreventfire.

Text IndicatorsListingsindicatedby“-”(hyphen)concernenumerations.Listingsindicatedby“•”(bulletpoint)describestepstoperform.

Service and Technical SupportForinformationaboutspecificadjustments,maintenanceorrepairjobswhicharenotdealtwithinthismanual,pleasecontactthesupplieroftheproduct.Theywillalwaysbewillingtohelpyou.Makesureyouhavethefollowingspecificationsathand: - product name - serial number

Youcanfindthisdataontheidentificationplate.

1 INTRODUCTION

1.1 Identification of The Product

Theidentificationplatecontains,amongotherthings,thefollowingdata: - product name - serial number - supplyvoltageandfrequency - power consumption

1.2 General Description

TheOS-3controlboxisanenergysavingcontrolunitdesignedtobeusedforcontrollingexhaustfansinvehicleexhaustsystems,withorwithoutaparticlefiltrationsystem.Togetherwithapressureswitchandoptionaltemperatureswitch,thisenergysavingcontrollermakesafullyautomaticsystemforthe

controlofthevehicleexhaustfan.Thecontrollercanbesetforbothmanualorautomaticcontrolofthefan.Dependingontheconfigurationofasystem,severaloptionsforswitchesandremotestartfunctionsareavailable.Thetwomostcommontypesofswitchesthataretypicallyusedareapressureswitchtodetectpressuredifferencesinthesystemwhenavehicleisconnected,and,anoptionaltemperatureswitchtodetecttemperaturelevelsinthesystemalsocreatedwhenavehicleisconnected.

TheOS-3alsoincludesanalarmoutput,whichcanbeusedforstatusoutputtoanonsitecontrolsystem(byothers).Abuilt-indelayofffunctionwillensurethatthefancontinuestorunforsometimeafterthevehiclehasbeendisconnected,thisensuresallofthetoxicgasesintheductsystemwillbeexhaustedoutoftheductingbeforethefanstops.Thedelayofftimecaneasilybeadjustedbetween3minutes-60minutes.

1.3 Product Combinations

TheOS-3controlboxisdesignedinconjunctionwithPlymoventvehicleexhaustextractionsystemcomponentsincludingPlymoventfansandSTR,VSRandSBTrailsystemsspecificallyforemergencyresponseandfirevehicleapplications.

1.4 Technical Specifications

LxWxH 15.75”x6”x11.75”(400mmx152mmx298mm)

MountingHoleDiameter .4”(10mm)diameterholes

MountingHoleLocation 14.15”x10.15”(359mmx258mm)oncenters

Weight 25lbs(11.34kg)

BoxRating NEMA 12

CompliantWith CE,NFPA,cUL*

DelayOffTimerRange 3minutes-60minutes

*Formostup-to-dateULinformation,includingonPlymovent,pleasevisittheonlinecertificationsdirectoryatwww.ul.com.

Refertotheavailableproductdatasheetfordetailedproductspecifications.

1.5 Ambient Conditions

Operatingtemperature: - min. - nom. - max.

- 41°F(5°C) - 68°F(20°C) - 104°F(40°C)

Max.relativehumidity 80%Storageconditions - 41-104°F(5-40°C)

- relativehumiditymax.80%Suitable for outdoor use no

1.6 Transport of The Unit

TheOS-3controlboxisdeliveredasself-containedexhaustsystemcontrollercompletewithfunctionsformanualrun,andautomaticstartwithdelayoffandstop.

Themanufacturercannotbeheldliableforanydamagetotheunitduetoshippingormishandling.Alwayshandletheunitandtheaccompanyingoptionsand/oraccessories,ifany,withcare.

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2 PRODUCT DESCRIPTION

2.1 Operation

Thecontrollercanbesetforbothmanualorautomaticcontrolofthefan.Dependingonsystem,differentswitchesforstartingthesystemcanbeused.Mainlytwotypesofswitcheswillbeused;pressureswitchtodetectpressuredifferenceinsystemsandtemperatureswitchestodetecttemperaturelevelinthesystem.

TheOS-3controlboxalsoincludesavisiblealarmdevice,whichcanbeusedforstatusoftheairflowintheexhaustsystem.Abuiltin“afterrunningtime”functionwillsecurethattoxicgasesintheductsystemwillbeexhaustedoutoftheductingbeforethefanstops.Theafterrunningtimecaneasilybeadjustedbetween3minutes-60minutes.

Whenthecontrolunitissetinto“automatic”position,theexhaustfanisstartedbyasignalfromanexternallymountedpressure,or/andtemperatureswitch.Normallythesystemisactivatedbythepressureswitchandkeptrunningbytheoptionaltemperatureswitch.

2.1.1 Pressure switch

Thepressureswitchreactstoanincreaseinpressurewithinthehose(positivepressure)whichoccursinthesystemwhenavehicleisstarteduporattachedwhileitisrunning.Thepressureswitchisadjustabletoaccomodatevariousenginesizes.Adjustmentstothisswitchshouldonlybeperformedbyauthorizedservicetechnician.

2.1.2 Optional: Temperature switch

Theoptionaltemperatureswitchdetectswhenthetemperatureinthesystemhasreachedbetween90°Fto130°F(32°Cto54°C)(tobedeterminedandadjustedbyanauthorizedservicetechnicianonly).

Thistemperatureriseoccurswhenarunningvehicleisattachedtothesystem,andwillensurethesystemstaysrunningwhilethevehicleisinoperation.

2.1.3 Automatic Mode

Thismodeofoperationallowsforeverydayusewhenexitingthefirestationforemergencycalls.Whentheengineisstarted,thepressureswitchcloses,thiscompletesthecircuittothecontrolboxcausingthefantoturnon.Whentheengineturnsoffortheapparatusleavesthefirestation,thepressureand/ortemperatureinthesystemdecreasesandthecontrolboxenteresintoadelayoffmode.Oncethetimerhascompletedits(adjustable)timedelay,thefanstopsafterthepresetruntimeisup.

2.1.4 Manual Mode

WhenthecontrolboxissettotheManualRunMode,theexhaustfanwillruncontinuously.Thisshouldbeutilizedforstationaryrunningofthevehiclesinthefirestationformaintenancechecks.WhileintheManualRunModeandrunningavehicleatHIGHIDLE,operationshouldbelimitedto1500RPMfor5minutes.ToexitManualRunMode,presstheSTOPbutton.ThesystemwillshutdownandautomaticallyreturntoAUTOSTARTandbereadyforthenextemergencycall.For2007ornewerdieselvehicleswithDPF(DieselParticulateFilter)unitsshouldneverbeallowedto“regenerate”whileconnectedtotheexhaustsystem.Vehicleswhichhaverecentlyundergone“regeneration”shouldnotbeconnectedtothesystemuntilnormalexhaustgasoperatingtemperatureshavereturned.

2.1.5 Stop Mode

Whenpressingthestopbutton,thefanwillstopimmediately,andafterashortperiodoftime(2-3seconds),thecontrolboxwillautomaticallymovebackintoautomaticmode.Thisisabuilt-insafetyfunctionwhichwillreducetheriskofhavingexhaustgasleakageinthesystemduetooperatorerror.

2.1.6 Alarm Mode

Thealarmdevicewilldetecthighpressurelossacrosstheoptionalfilterunit.WhentheFanOnLEDindicatorlightisflashing,thepressureacrossthefilterhasexceededtheacceptablerange,thefiltershouldbereplacedassoonaspossible to maintain proper system operation.

3 SAFETY

GeneralThemanufacturerdoesnotacceptanyliabilityfordamagetotheproductorpersonalinjurycausedbyignoringthesafetyinstructionsinthismanual,orbynegligenceduringinstallation,use,maintenance,andrepairoftheproductmentionedonthecoverofthisdocumentandanycorrespondingaccessories.Specificworkingconditionsorusedaccessoriesmayrequireadditional safety instructions. Immediately contact your supplier ifyoudetectapotentialdangerwhenusingtheproduct.

The user of the product is always fully responsible for observing the local safety instructions and regulations.

User Manual - Everyoneworkingonorwiththeproductmustbefamiliarwiththecontentsofthismanualandmuststrictlyobservetheinstructionstherein.Themanagementshouldinstructthepersonnelinaccordancewiththemanualandobserveallinstructionsanddirectionsgiven.

- Neverchangetheorderofthestepstoperform. - Thisusermanualshouldalwaysbekeptwiththeproduct,aswellasaduplicatecopybekeptbythefiredepartmentorcityservice department after installation.

- Theexamplesanddiagramsinthismanualareincludedsolelyforillustrativepurposes.Becauseofthemanyvariablesandrequirementsassociatedwithanyparticularinstallation,Plymovent cannot assume responsibility or liability for actual usebasedontheexamplesanddiagrams.

- NopatentliabilityisassumedbyPlymoventwithrespecttouseofinformation,circuits,orequipmentdescribedinthismanual.

- Reproductionofthecontentsofthismanual,inwholeorinpart,withoutpriorwrittenpermissionofPlymoventisprohibited.

Pictograms and Instructions On The Product (if present) - Thepictograms,warningandinstructionsattachedtotheproductarepartofthesafetyfeatures.Theymustnotbecoveredorremovedandmustbepresentandlegibleduringtheentirelifeoftheproduct.

- Ifpictogram,instructionsorlabelsontheproductbecomedamaged,missingorillegibleimmediatelydiscontinueuseoftheunitandreplaceorrepairdamagedorillegiblepictogram,warningsandinstructions.

- Contactyourlocalauthorizedservicetechnicianforsupport.

UsersTheuseofthisproductisexclusivelyreservedtoauthorized,trainedandqualifiedusers.Temporarypersonnelandpersonnel

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intrainingcanonlyusetheproductundersupervisionandresponsibilityofskilledtechnicians.

Intended Use1

TheproducthasbeendesignedasacontrolboxtooperateaPlymoventexhaustextractionfan.Usingtheproductforotherpurposesisconsideredcontrarytoitsintendeduse.Themanufactureracceptsnoliabilityforanydamagesorinjuryresultingfromsuchuse.Theproducthasbeenbuiltinaccordancewithstate-of-the-artstandardsandrecognizedsafetyregulations.Onlyusethisproductwheninaccordancewithitsintendeduseandtheinstructionsexplainedintheusermanual.

Technical SpecificationsThespecificationsgiveninthismanualmustnotbealteredfromtheinformationgivenherewithin.Thisinformationissubjecttochangeatanytimewithorwithoutnotice.

ModificationsModificationof(partsof)theproductisnotallowed,exceptthebottomplate,whichisallowedtobeusedasentrancepointforexternalcabling.

Installation - Theinstallationofthisproductisexclusivelyreservedtoauthorized,well-trainedandqualifiedelectrician.

- All installations must meet any and all applicable local laws, regulations,standardsandrequirements.

- Itistheresponsibilityoftheinstallingpartytoensurethatallcodesaremetduringtheinstallationofthiscontrolsystem.Anyinspectionsrequiredarethesoleresponsibilityoftheinstallingparty.

- Inspecttheproductandcheckitfordamage. - Verifythefunctioningofthesafetyfeatures. - Neverinstalltheproductinfrontofentrancesandexitswhichmustbeusedforemergencyservices.

- Makesurethattheworkshop,inthevicinityoftheproduct,containssufficientapprovedfireextinguishers.

- Itisrecommendedthatthecontrolboxbemountedatapproximately6feet(1.8m)abovefinishedfloorleveltofacilitate operator use and service if necessary.

Use - Checktheworkingenvironment.Donotallowunauthorizedpersonstoentertheworkingenvironment.

- Protecttheproductagainstwaterandhumidity. - Stayalertandkeepyourattentiontoyourwork.Donotusetheproductwhenyouareundertheinfluenceofdrugs,alcoholor medicine.

- Makesuretheroomisalwayssufficientlyventilated; thisappliesespeciallytoconfinedspaces.

Service, maintenance and repairs

WARNING!Maintenanceshouldonlybeperformedbyauthorized,qualifiedandtrainedpersons(skilled)usingappropriateworkpractices.WARNING!Electrocution hazardDisconnectmainsbeforeservicing.Failuretodosocouldresultinseriouspersonalinjuryordeath.

1 “Intendeduse”asexplainedinEN-ISO12100istheuseforwhichthetechnicalproductissuitedasspecifiedbythemanufacturer,inclusiveofmanufacturersdirectionsinthesalesbrochure.Incaseofdoubt,itistheusewhichcanbededucedfromtheconstruction,themodelandthefunctionofthetechnicalproductwhichisconsiderednormaluse.Operatingthemachinewithinthelimitsofitsintendedusealsoinvolvesobservingtheinstructionsintheusermanual.

4 INSTALLATION

WARNING!Donotattemptinstallationofthisunitunlessyouarefamiliarwiththenecessarytools,equipment,utilityconnectionsandpotentialhazards.Installationshouldbeperformedonlybyaqualifiedservice provider. Failure to do so could result in reducedperformanceoftheunit,seriouspersonalinjuryordeath.WARNING!Fire hazardNeverinstallthecontrolboxinareaswithflammablegases.ATTENTIONTheOS-3 controlboxisdeliveredwithoutcablesforexternalfieldwiring.Allinterconnectcables/wiresizeusedshallbesuppliedbyothersandcomplywithUL,NECandallothernationalandlocalstandardscodes.TheglandsusedforinsertingthecableintotheOS-3 controlboxshouldbeplacedinthebottomofthecasing.ThecableshouldfittightlyintheglandtopreventanymoistureenteringtheinsideoftheOS-3 control box.

4.1 Unpacking

Checkthattheproductiscomplete.Thepackageshouldcontain: - OS-3 control box - doorkey

4.2 Electric connection

ConnecttheOS-3inaccordancewiththeseparatelysuppliedelectricaldiagram.

CAUTION!Electric connection to be executed in accordance withlocalrequirements.EnsurecompliancewiththeEMCregulatoryarrangements.WARNING!Makesurethemachineissuitableforconnectiontothelocalmains.Informationabouttheconnectionvoltageandfrequencycanbefoundontheidentificationplate.ATTENTIONThethermalrelayshouldbesetaccordingtotheoverloadmentionedontheidentificationplateonthemotor.

4.3 Primary Wiring Procedure

4.3.1 Terminal Block 1

Islocatedinthelowerleft-handcorneroftheOS-3controlboxandconsistsofincomingpowerelectricalterminalblocksL1,L2,L3.Itisimportanttonoteonsinglephaseboxes,L3willnotbeinstalled.OutgoingpowertothefanmotorviatheoverloadoutputlocationsT1,T2,T3onsinglephasecontrolboxestheT3terminalwillbeoccupiedbyawirelooping“backthrough”thecontactor,thisisnecessaryforproperoperationandshouldnotbealtered.Groundshouldbelandedonterminalstriponthegreenandyellowterminalblock,lowvoltagecontrolwiring

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terminalblocks(0,24Vand1through8)andelectricaloverloadusesforprotectionforbothprimary(F1,F2)andsecondary(F3).

NOTE: Primarylinevoltagemustnotbegreaterorlessthan8%ofratedvoltagelistedonvoltagetap.Forexample,Tap120volt(110–130voltagerangeisacceptable)forexcessivelylowlinevoltage,abuckboosttransformermayberequired.(Suppliedbyothers).

4.3.2 Primary Voltage Wiring

OntherightsideoftheterminalblockisthefirstterminalblockmarkedGND(greenground),hereyouwillconnectyourgroundwire(properlysizedperNEC).InthesecondterminalblockmarkedL1,youwillconnectyourfirstpowerwire.InthethirdterminalblockmarkedL2,youwillconnectyoursecondpowerwire.Forthefourthterminalblock(whenapplicable),markedL3,youwillconnectyourthirdpowerwire.

NOTE: Thelinesupplyvoltagefromyourbuilding,whichwillsupplyyourmotor,shallbeconnecteddirectlytoL1,L2forsinglephaseandL1,L2,andL3for3-phase.Re-checkthatratedvoltagecorrespondswithsupplyvoltagetoavoiddamagetoelectricalcomponentsorcontrolwiring.

Table2Aonpage13andTable2Bonpage14showthefancomponentsizingcharts.

Pleaserefertolocalcodesandrequirements,thesewilltakeprecedenceoverthesupplierwiringchartatthebackofthismanual.

4.3.3 Field Power Wiring of Control Box, Safety Disconnect and Fan Motor

TheprimarywiringoftheelectricalsystemmustberatedforthemaximumampsandHPratingofthefanmotorloadaswellasthewiringvoltagedrop,whichiscalculatedforthedistance,youarerunning.SeePlymoventWiringChartinthebackofthismanualasaguideforwiring.ItiscriticaltoalwaysfollowlocalcoderequirementsforselectingwireininstanceswheretheydifferfromPlymoventpublishedrecommendations.

NOTE: Fieldwiring,powersupplypanelandelectricalsafetydisconnectareprovidedbyothers.Plymoventassumesnoliability for any electrical installation and all national and local codesandstandardsshouldbefollowed.

4.4 Primary Wiring Procedures (Control Wiring)

4.4.1 Control Voltage Wiring

Theterminalblocks0,24Vand1through8areusedforlowvoltagecontrolwiringofoptionalwirelesscontrolsystem,remotemountedpressureswitchforstartingfunctions,cleanfilterindicatorandtemperatureswitch.AnoptionalremotealarmrelayconnectionisavailableforconnectiontoBuildingAutomationSystems(BAS).

4.4.2 Pressure Switch / Temperature Switch (engine start/stop)

Thepressureswitchandoptionaltemperatureswitch,whichissoldseparately,willbewiredtoterminalblock1and2.Ifmorethanonepressure/temperatureswitchisutilizedinasystemtheymustbewiredinparalleltoachieveproperoperation.

NOTE: Controlwiressupplyingterminalblock1and2mustbeaminimumof16AWG/1.29mm²,smallerwiresizingwillresultinimproper system operation.

Amomentarymanualpushbuttonstartswitchcanalsobeplacedinparallelinthiscircuitforremotestartingofthesystem.

4.4.3 Remote Alarm (optional)

Terminals 3, 4, and 5 are a relay dry contact connection for a BuildingAutomationSystem(BAS).Terminalblock3providesthecommonconnection,terminal4providesanormallyclosedcontact connection and terminal 5 provides a normally open contact connection.

NOTE: Relay output is a dry contact potential free and will requireadditionalcontrolequipmentdependingonitsuse.

4.4.4 Pressure Switch (filter alarm)

Anexhaustventilationparticulatefilter(suchasthePlymoventMultiSmokeFilter)maybeprovidedwithanadjustablepressureindicatorswitch,whichmonitorsthefiltersusefullife.Terminals6and7(potentialfree)areutilizedtoconnectandoperatethepressureindicatorswitch.Whenthefilterbecomesdirty,thepressureswitchwillsendasignaltothecontrolboxandin-turnwillflashtheFanOnLEDindicatorlight,locatedonthefaceoftheOS-3controlpanel,whenthefanmotorisrunning.Indicatingafilterchangeisrequired.

4.5 Transformer Wiring Procedure

4.5.1 Multi-tap Control Transformer

DesignedbyPlymoventtoallowthefieldelectriciantheabilitytoselecttheprimaryvoltageofhischoice.Thisvoltageselectionrangesfrom120voltthrough600voltVAC.Thetransformerhasbeendesignedtooperateinboth50and60Hzenvironments.

NOTE: Primarylinevoltagemustnotbegreaterorlessthan8%ofratedvoltagelistedonvoltagetap.Forexample,Tap120volt(110–130voltagevariantacceptable)forlowlinevoltage,abuckboosttransformermayberequired.(Suppliedbyothers).

4.5.2 Primary Voltage Connection

Onthetoprightsideoftransformeryouwillfindaterminalblockwith8pointsofconnection.Commonblackwireisconnectedtothetopterminalblock(blacktoyellowwire)andwillalwaysremaininthispositionregardlessofthevoltageadjustmentthatyouwillbemaking.Thevoltageadjustinggraywireispresetforthevoltageordered.Youmayberequiredtorepositionthevoltageadjustingwiretothelinesupplyvoltagepresentatyourinstallation/facility.Forexample,adjustingto120voltlinevoltage,movethevoltageadjustingwiretowiretapsecondfromthetopofterminalblock(blacktowhite).Viewyellowlabelforcorrectwiretapcolorforeachavailablevoltage.

NOTE: Improperwiringwillresultindamageofotherelectricalcomponents.Re-checkthatratedvoltagecorrespondswithsupplyvoltagetoavoiddamagetoelectricalcomponents.

Always ensure power is off and all required procedures for facility(suchaslockouttagout)areproperlyfollowedbeforemakinganyadjustmentstothecontrolsystem.

WARNING!Procedureswhich,ifnotcarriedoutwiththenecessarycaution,maydamagetheproductand/orcauseseriouspersonalinjury.

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4.5.3 Secondary Voltage Connection

Ontheleftsideofthetransformeryouwillviewaterminalblockwith2pointsofconnection:oneorangeandonepurple.Thewire taps will produce 24 VAC.

NOTE: Thesecondaryvoltageconnectionsarepresetfromthefactory,andshallneverbechanged.

4.5.4 Electrical Wiring

Allelectricalwiringwhichincludesprimary,secondaryandcontrolwiringmustbedonebyacertified/licensedelectricianandinaccordancewiththeNEC.

4.6 Pressure Switch Procedure

4.6.1 Pressure Switch

Plymoventhasincorporatedapressureswitch,whichsensestheexhaustgaspressuregeneratedbythevehicle.Thisadjustablepressureswitchallowstheelectricalcontrollertostarttheoperationofthefan.Thepressureswitchhasbeenpresetat0.1”in.H2Oandisfieldadjustable.

4.6.2 Electrical Wiring

Thepressureswitchutilizesaparallelconnectionwithanoptionaltemperatureswitch,whichisconnectedtoterminals1and2locatedonterminalblock1(TB1).Boththepressureandthetemperatureswitchwillmaintainanormallyopenpositionwhenvehicleisnotinoperation.

NOTE: Electricalwiringprovidingsignaltotemperatureandpressureswitchmustbe16AWG/1.29mm²wire(minimum)sizeandshouldnotberanontopoffluorescentlightfixturesorwithotherwirecablesduetoinducedcurrentandorelectricalinterference.Controlwiringmustbedonebycertified/licensedelectrician.

4.6.3 Pressure Adjustment Procedure

Thepressureswitchallowsforfieldadjustmentsbyplacingascrewdriverintheslottedscrewinthebackoftheswitch.Byturningthedialclockwise(in)youwillincreasethesensitivityandbyturningthedialcounterclockwise(out)youwilldecreasethesensitivity.Toresetthepressureswitchadjustmentinthefield,withthepoweroff,disconnectthe2lowvoltagewiresandconnectacontinuitymeteracrossthe2terminalsoftheswitchandslowlyturnadjustingscrewclockwise(in)untilyougetcontinuity(contactsclosed),thenturnthescrewcounterclockwise(out)1completeturn.Thepressuresetting,mayvaryupordowndependingonthevehiclesoutputpressure.Toaccuratelyadjustthepressureswitchstartthevehicleandcheckthatthefanstartsimmediately,turnoffvehicleandtheexhaustfanshouldrunformaximum5minutes.

NOTE: Ifexhaustfandoesnotstart,adjustthepressureswitchbyturningadjustingscrewclockwise(in)1/8ofaturnandrestartthevehicle.Ifthefanstilldoesnotstartrepeatprocedure.Iffanstartswhenthevehicleisnotrunningdecreasepressuresettingonpressureswitchbyturningadjustmentscrewcounterclockwise(out)1/4turn.

4.7 Temperature Switch Procedure

4.7.1 Optional Temperature Switch

Plymoventhasincorporatedanoptionaltemperatureswitch,whichsensestheexhaustgastemperaturegeneratedbythe

vehicle.Thisadjustablebi-metaltemperatureswitchallowstheelectricalcontrollertomaintaintheoperationofthefanforaslongasthevehicleisrunning.Theadjustmentscalerangesfrom90°F/30°Cto130°F/55°C,whichallowsthefieldinstallertheabilitytoadjustthetemperaturesetting.

4.7.2 Electrical Wiring

Thetemperatureswitchutilizesaparallelconnectionwiththepressureswitch,whichisconnectedtoterminals1and2locatedatterminalblock1(TB1).Boththetemperatureandthepressureswitchwillmaintainanormallyopenpositionwhenvehicleisnotinoperation.

NOTE: Electricalwiringprovidingsignaltotemperatureandpressureswitchmustbe16AWG/1.29mm²wiresizeandshouldnotberanontopoffluorescentlightfixturesorwithotherwirecables due to induced current and or electrical interference. Controlwiringmustbedonebycertified/licensedelectrician.

4.7.3 Temperature Adjustment Procedure

Thetemperatureswitchallowsforfieldadjustmentbyplacingascrewdriverintheslotteddialinthecenteroftheswitch.Byturningthedialcounterclockwiseyouwilldecreasethetemperaturesettingandbyturningthedialclockwiseyouwillincreasethetemperaturesetting.Therecommendedsettingwillbebetween120°F/49°Cto130°F/55°C.Toaccuratelyadjustthetemperatureswitchstartthevehicleandallowtorunfor10minutes,turnoffvehicleandtheexhaustfanshouldrunforapproximately5to15minutesafterthevehiclehasbeenturnedoff.

NOTE:Ifexhaustfancyclesonandoffwhenvehicleisrunning,itwillbenecessarytoincreasethetimersettinglocatedatcontrollercard(seeinstructions).Iffanstartswhenthevehicleisnotrunning,increasetemperaturesettingontemperatureswitch.

4.8 Wireless Control System Procedure

4.8.1 Optional Wireless Control System

TheWirelessTransmitterandReceiverisanoptionalfeaturedesignedtofacilitateremotelymountingthepressureswitchand/ortemperatureswitchonthecrabsofaSTRArailsystemandontheductworksystemoftheSBTAtracksystem.Thereceiverincludesanexternalantenna.Thereceiverutilizesspreadspectrumtechnologyandoffersexcellentelectromagneticinterference(EMI)tolerance.UnitsaredesignedtoworkwiththePlymoventWireless2400MHztransmittersandhasarangeof500feet.TheseproductswillnotinterferewithorbeaffectedbyWi-Fisystems.Thelearningreceivercanlearnupto24differenttransmitters.Thereceivershalloperateon24VACandbemountedinanon-metallicenclosurewithaclearseethroughlidapproximately8’to10’(2.4mto3m)abovethefinishedfloorlevel,directlyabovetheOS-3AutomaticController.

4.8.2 Electrical Wiring Connections

Connecttheredwirelabeled12-24Vtoterminal24VonterminalstripTB1,connecttheblackwirelabeledGRNDtoterminal0onterminalstripTB1,connectthebluewirelabeledCtoterminal1onterminalstripTB1,connecttheorangewirelabeledNOtoterminal2onterminalstripTB1insideOS-3controlbox.

ForWirelessSystemprogrammingrefertotheWirelessControlSystem Product Manual.

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5 MAINTENANCE

TheOS-3requiresnospecificmaintenance.

6 TROUBLESHOOTING

IftheOS-3 does not function correctly, please contact your local authorizeddealer/technician.

7 SPARE PARTS

PleaserefertoTable1onpage10toviewthesparepartsavailablefortheOS-3.

Fig.7.1 Exploded view

• A-F3• B-Transformer• C-F1/F2• D-Contactor• E-OverloadRelay• F-AdjustingHoleforTimer• G-CircuitBoard• H-Membrane

8 ELECTRICAL DIAGRAM

PleaserefertoFigures8.1-8.4(below)andFigure1onpage12 to viewtheelectricaldiagramsfortheOS-3.

Table2Aonpage13andTable2Bonpage14showtheFanComponentSizingChartsforthreeandonephase.

Fig.8.1 SwitchDetail

Fig.8.2 Terminal Detail

Fig.8.3 System Detail

9 DISPOSAL

Afterlifeoftheproduct,disposeitofinaccordancewithstateorlocalregulations.

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Table 1 Spare Parts

Plymovent Number

Voltage/Phase*

Rated Amp load for ctrl

box**Contactor Overload

Relay F1 & F2*** F3***

OS-3 for 1/2 HP fan

115V/1ph 7.6 00000100389 00000100390 00000116071 00000101409

230V/1ph 3.8 00000100389 00000101443 00000116054 00000101409

230V/3ph 1.78 00000100389 00000101443 00000116054 00000101409

460V/3ph 0.81 00000100389 00000102475 00000116067 00000101409

575V/3ph 0.66 00000100389 00000102475 00000116067 00000101409

OS-3 for 3/4 HP fan

00000116168 115V/1ph 10.6 00000100389 00000100390 00000116071 00000101409

00000116169 230V/1ph 5.3 00000100389 00000100390 00000116054 00000101409

00000116170 230V/3ph 2.41 00000100389 00000101443 00000116054 00000101409

00000116171 460V/3ph 1.1 00000100389 00000101443 00000116067 00000101409

00000116172 575V/3ph .88 00000100389 00000101443 00000116067 00000101409

OS-3 for 1 HP fan

00000116118 115V/1ph 12.8 00000100389 00000100390 00000116071 00000101409

00000116119 230V/1ph 6.4 00000100389 00000100390 00000116054 00000101409

00000116120 230V/3ph 3.17 00000100389 00000101443 00000116054 00000101409

00000116121 460V/3ph 1.43 00000100389 00000101443 00000116067 00000101409

00000116140 575V/3ph 1.12 00000100389 00000101443 00000116067 00000101409

OS-3 for 1.5 HP fan

00000116142 115V/1ph 17 00000102473 00000102576 00000116071 00000101409

00000116143 230V/1ph 8.8 00000100389 00000100390 00000116054 00000101409

00000116144 230V/3ph 4.36 00000100389 00000100390 00000116054 00000101409

00000116145 460V/3ph 1.97 00000100389 00000101443 00000116067 00000101409

00000116146 575V/3ph 1.56 00000100389 00000101443 00000116067 00000101409

OS-3 for 2 HP fan

00000116173 115V/1ph 20.4 00000102473 00000102576 00000116071 00000101409

00000116174 230V/1ph 10.6 00000100389 00000100390 00000116054 00000101409

00000116175 230V/3ph 6.25 00000100389 00000100390 00000116054 00000101409

00000116176 460V/3ph 2.83 00000100389 00000101443 00000116067 00000101409

00000116177 575V/3ph 2.06 00000100389 00000101443 00000116067 00000101409

OS-3 for 3 HP fan

00000116122 230V/1ph 14.6 00000100389 00000100390 00000116054 00000101409

00000116123 230V/3ph 8.4 00000100389 00000100390 00000116054 00000101409

00000116124 460V/3ph 3.8 00000100389 00000101443 00000116067 00000101409

00000116136 575V/3ph 3.04 00000100389 00000101443 00000116067 00000101409

OS-3 for 5 HP fan

00000116125 230V/1ph 22 00000102473 00000102576 00000116054 00000101409

00000116126 230V/3ph 13 00000100389 00000100390 00000116054 00000101409

00000116127 460V/3ph 5.9 00000100389 00000100390 00000116067 00000101409

00000116137 575V/3ph 4.72 00000100389 00000100390 00000116067 00000101409

OS-3 for 7.5 HP fan

00000116128 230V/1ph 32 00000102474 00000102477 00000116054 00000101409

00000116129 230V/3ph 19.2 00000102474 00000102477 00000116054 00000101409

00000116130 460V/3ph 8.66 00000100389 00000100390 00000116067 00000101409

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Plymovent Number

Voltage/Phase*

Rated Amp load for ctrl

box**Contactor Overload

Relay F1 & F2*** F3***

00000116138 575V/3ph 6.93 00000100389 00000100390 00000116067 00000101409

OS-3 for 10 HP fan

00000116131 230V/1ph 38.8 00000102474 00000116837 00000116054 00000101409

00000116132 230V/3ph 25.8 00000102474 00000102477 00000116054 00000101409

00000116133 460V/3ph 11.7 00000100389 00000100390 00000116067 00000101409

00000116139 575V/3ph 9.35 00000100389 00000100390 00000116067 00000101409

OS-3 for 15 HP fan

00000116134 230V/3ph 37.6 00000102474 00000116837 00000116054 00000101409

00000116135 460V/3ph 17 00000102474 00000102477 00000116067 00000101409

00000116141 575V/3ph 13.6 00000100389 00000100390 00000116067 00000101409

Common Parts

Transformer 00000100381 Multiple tap

Front panel Membrane 00000101644 N/A

Door Key 00806013040 N/A

Circuit Card 00000101326 24 VAC

*Voltagenottoexceed8%listedvoltage.For208Vadjustmentoftapontransformermayberequired(byothers).**AmploadisacquiredforaPlymoventFanrunningatoptimalvoltage.Adjustmentmayberequiredbasedonlocalvoltages(tobedonebyproperpersonnel/technician).***Minimumorderquantitymayberequired.

This list is subject to change without notice. Please refer to your local dealer/representative for most up to date documentation.

Table 1 Spare Parts Continued

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Figure 1 Wiring Chart

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Table 2A / Three Phase: Fan Component Sizing Chart

Plymovent Product No.

HPRating Voltage NEC Table 430.250Amps

WireSizeTHHNAWG

LengthofWireinFeet(Meters)StarttoFinish*

Circuit BreakerSize

From To*

FUA-1300-1-AM

1/2

208 2.4 14 0 478(145.6) 15A

FUA-1300-2-AM 230 2.2 14 0 576(175.5) 15A

460 1.1 14 0 2,306(702.8) 15A

575 .9 14 0 3,524(1,074) 15A

FUA-1800-1-AM

3/4

208 3.5 14 0 327(99.6) 15A

FUA-1800-2-AM 230 3.2 14 0 396(120.7) 15A

460 1.6 14 0 1,585(483.1) 15A

575 1.3 14 0 2,439(743.4) 15A

FUA-2100-1-AM

1

208 4.6 14 0 249(75.8) 15A

FUA-2100-2-AM 230 4.2 14 0 302(92) 15A

460 2.1 14 0 1,208(368.1) 15A

575 1.7 14 0 1,865(568.4) 15A

FUA-2700-1-AM

1.5

208 6.6 14 0 173(52.7) 15A

FUA-3000-1-AM 230 6 14 0 211(64.3) 15A

FUA-2700-2-AM 460 3 14 0 845(257.5) 15A

FUA-3000-2-AM 575 2.4 14 0 1,321(402.6) 15A

TEV-359-60 2

208 7.5 14 0 152(46.3) 15A

230 6.8 14 0 186(56.6) 15A

460 3.4 14 0 746(227.3) 15A

575 2.7 14 0 1,174(357.8) 15A

TEV-3110-60

3

208 10.6 14 0 108(32.9) 15A

FUA-4700-1-AM 230 9.6 14 0 132(40.2) 15A

FUA-4700-2-AM 460 4.8 14 0 528(160.9) 15A

575 3.9 14 0 813(247.8) 15A

TEV-559-60 5

208 16.7 10 0 173(52.7) 30A

230 15.2 12 0 132(40.2) 20A

460 7.6 14 0 333(101.4) 15A

575 6.1 14 0 519(158.1) 15A

TEV-585-60 7.5

208 24.2 8 0 191(58.2) 40A

230 22 10 0 146(44.5) 30A

460 11 14 0 230(70.1) 15A

575 9 14 0 352(107.2) 15A

TEV-745-60 10

208 30.8 8 0 150(45.7) 40A

230 28 8 0 182(55.4) 40A

460 14 12 0 287(87.4) 20A

575 11 14 0 288(87.7) 15A

TEV-768-60 15

208 46.2 6 0 158(48.1) 60A

230 42 6 0 193(58.8) 50A

460 21 10 0 305(92.9) 30A

575 17 10 0 472(143.8) 30A*Ifwirelengthislongerthandistancelisted,upsizetonextlargerAWGNote:Guidelinesaresubjecttochangewithoutnotice.Datasuppliedfromourprimarymotorsupplier.Pleaseconfirmattimeoforder.Plymoventassumesnoliabilityforanyelectricalinstallation,alllocal,city,andthe2014NationalElectricCodemustbefollowed.Thischartisaminimumstandardandtobeusedasaguidelineonly.Basedona3%voltagedropforbranchcircuits.

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Table 2B / Single Phase: Fan Component Sizing Chart

Plymovent Product No.

HPRating Voltage NEC Table 430.248Amps

WireSizeTHHNAWG

LengthofWireinFeet(Meters)StarttoFinish*

Circuit BreakerSize

From To*

FUA-1301-AM 1/2

115 9.8 12 0 88(26.8) 20A

208 5.4 14 0 184(56) 15A

230 4.9 14 0 224(68.2) 15A

FUA-1801-AM 3/4

115 13.8 10 0 100(30.4) 30A

208 7.6 14 0 130(39.6) 15A

230 6.9 14 0 159(48.4) 15A

FUA-2101-AM 1

115 16 10 0 86(26.2) 30A

208 8.8 12 0 179(54.5) 20A

230 8 12 0 217(66.1) 20A

FUA-2701-AM

1.5

115 20 10 0 70(21.3) 30A

FUA-3001-AM 208 11 12 0 143(43.5) 20A

230 10 12 0 174(53) 20A

TEV-359-60 2

115 24 8 0 92(28) 40A

208 13.2 12 0 119(36.2) 20A

230 12 12 0 145(44.1) 20A

FUA-4701-AM

3

208 18.7 10 0 134(40.8) 30A

TEV-3110-60 230 17 10 0 163(49.6) 30A

460 ** 14 0 325(99) 15A

TEV-559-60 5

208 30.8 8 0 130(39.6) 40A

230 28 8 0 158(48.1) 40A

460 ** 14 0 209(63.7) 15A

TEV-585-60 7.5

208 44 6 0 144(43.8) 50A

230 40 6 0 175(53.3) 50A

460 ** 10 0 347(105.7) 30A

TEV-745-60 10

208 55 4 0 184(56) 60A

230 50 6 0 140(42.6) 60A

460 ** 10 0 286(87.1) 30A*Ifwirelengthislongerthandistancelisted,upsizetonextlargerAWG**2014NECTable430.248doesnotlist460voltsinglephasemotorsNote:Guidelinesaresubjecttochangewithoutnotice.Datasuppliedfromourprimarymotorsupplier.Pleaseconfirmattimeoforder.Plymoventassumesnoliabilityforanyelectricalinstallation,alllocal,city,andthe2014NationalElectricCodemustbefollowed.Thischartisaminimumstandardandtobeusedasaguidelineonly.Basedona3%voltagedropforbranchcircuits.

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