TJERNLUND CPC-3 User guide

TJERNLUND PRODUCTS, INC.

1601 Ninth Street • White Bear Lake, MN 55110-6794

PHONE (651) 426-2993 • (800) 255-4208

FAX (651) 426-9547

www.Tjernlund.com

REV. B

TJERNLUND SPECIFIED SYSTEMS

START-UP GUIDE

AND WARRANTY ACTIVATION FORM

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED

SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND

OPERATION OF THIS UNIT. READ THIS GUIDE THOROUGHLY BEFORE

ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE

INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT,

SERVICE OR MAINTENANCE POSSIBLY RESULTING IN FIRE, ELECTRICAL

SHOCK, CARBON MONOXIDE POISONING, EXPLOSION, OR PERSONAL

INJURY OR PROPERTY DAMAGE.

DO NOT DESTROY. PLEASE READ CAREFULLY AND

KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

INTRODUCTION: Completion of all the steps contained in this guide will verify that the all

Tjernlund Specified System products are operating properly. Follow the directions carefully;

step by step completion ensures thoroughness and allows Tjernlund to provide better support if

difficulties occur. This guide is normally completed in 15 minutes.

Upon completing the guide, please complete the attached warranty form and fax or mail a com-

pleted copy of the entire guide to Tjernlund Products.

IMPORTANT: IN ORDER TO ACTIVATE THE WARRANTY FOR ANY

TJERNLUND SPECIFIED SYSTEM PRODUCT THIS GUIDE MUST BE

COMPLETED AND RETURNED TO TJERNLUND PRODUCTS ALONG WITH

THE INCLUDED WARRANTY ACTIVATION FORM.

Specified Systems Start-Up Guide

A. System Restart

To ensure success in this process, please use the disconnect switch to power off every appliance served by the Auto-

Draft system. Verify that all "Call" LEDs on the CPC are unlit.

Next, power OFF the Tjernlund CPC-3 and VFD. Verify that all LEDs are unlit for both units.

Wait one minute for the VFD to completely shutdown.

Then, power ON the VFD and CPC-3 controller. Some LEDs on the VFD and the CPC-3 should become lit.

Wait one minute for CPC-3 to reinitialize.

B. CPC-3 Status Verification

Indicate the status of the following LEDs located on the CPC-3 by checking the corresponding box within the

appropriate table.

NOTES

If you are using the CPC-3 for a Draft application, verify that the some of the LEDs under the “Draft” heading (on your

LEFT hand side) are lit and record their status in the Draft table.

If you are using the CPC-3 for a Combustion Air application, verify that some of the LEDs under the “Combustion

Air” heading (on your RIGHT hand side) are lit and record their status in the Combustion Air table.

If you are using the CPC-3 for both Draft and Combustion Air applications, fill out the appropriate table for each

application.

IMPORTANT

If ANY of your indications fall within a shaded box, continue on to Section X-1 on page 10 and locate the corre-

sponding solution.

If NONE of your indications fall within a shaded box, continue on to Section C on page 2.

IMPORTANT CPC-3

INDICATORS

LIT UNLIT

Limit Status OK LED

VFD Status OK LED

Analog LED

Digital LED

Any Call LED

(Under Burner Heading)

Draft

IMPORTANT CPC-3

INDICATORS

LIT UNLIT

Limit Status OK LED

VFD Status OK LED

Analog LED

Digital LED

Any Call LED

(Under Burner Heading)

Combustion Air

C. CPC-3 Display Message Verification

Record the Actual Pressure

IMPORTANT

If the Actual Pressure on the top line of the CPC-3 display reads -0.60 or 0.15, continue to Section X-2 and X-4 on

page 11.

If the Actual Pressure on the second from the top line of the CPC-3 display reads -0.10 or 0.10, continue to the sec-

tion entitled X-2 and X-4 on page 11.

If the Actual Pressure of the CPC-3 display reads “Draft Inactive” or some values other than -0.60 or 0.15 for the

Actual Pressure on the first line for Draft systems, continue to Section E on page 2.

If the Actual Pressure of the CPC-3 display reads “Combustion Air Inactive” or some values other than -0.10 or

0.10 on the second from the top line for Combustion Air systems, continue to Section D on page 2.

Top Line Reads:

(Disregard if system is for Combustion Air only)

Second from Top Line Reads:

(Disregard if system is for Draft only)

D. Dip Switch Adjustment

Identify the set of Dip Switches which correspond to the application for which this system is set up.

IMPORTANT

For Draft applications, the following configurations should be

made to the set of Dip Switches on the left side of the CPC-3.

For Combustion Air applications, the following configurations

should be made to the set of Dip Switches on the right side of

the CPC-3.

After determining the appropriate Dip Switch set in the previous step:

Move the left Dip Switch (#2) down toward the floor.

Move the right Dip Switch (#1) up toward the ceiling.

Operation

Mode

Set

Point

Actual

Pressure

% Speed

Operation

Mode

Set

Point

Actual

Pressure

% Speed

Note: The above numbers have no meaning in regards to these steps--

they are merely placeholders. Your numbers do not need to match these.

E. VFD Status Verification

Determine which of the LEDs on the Status Panel, located below the red Display LED on the VFD, is lit.

If FREF is lit, continue on to record the status of Run and Alarm LEDs.

If an LED other than the FREF LED is lit, press the DSPL button until the FREF LED becomes

lit.

Indicate the status of the following LEDs located on the VFD by checking the appropriate box within the following table.

IMPORTANT

If ANY of your indications fall within a shaded box, continue on to Section X-3 on page 11 and locate the corre-

sponding solution.

If NONE of your indications fall within a shaded box, continue.

F. Transducer Set-Up Verification

Verify that the sensing tube is connected to the Transducer Port closest to you and furthest from the surface upon

which the transducer is mounted.

VFD

IMPORTANT CPC-3 INDICATORS

LIT

UNLIT

BLINKING

Run LED

Alarm LED

G. Beginning the System’s Test Mode

IMPORTANT

If using the system for both Draft and Combustion Air applications, perform the following procedure twice; first with

Draft and then with Combustion Air.

(1) Hold the Save Setting key on the CPC-3 for 5 seconds until the bottom line of the Display

reads "Keypad Open."

(2) Press the “Set Up” button corresponding to your application.

If the system is for Draft applications, press the “Set Up” button on the Draft (left) side the CPC-3.

If the system is for Combustion Air applications, press the “Set Up” button on the Combustion Air (right)

side of the CPC-3.

The LEDs on the side associated with the application you selected will become lit and the display will read, "Inducer

Setup Set Installation" for Draft applications and will read, “Combustion Air Setup Set Installation” for Combustion Air

applications.

(3) Verify Message on CPC-3 Display

If the CPC-3 Display reads “Inducer Inactive” on the top line for Draft or “Combustion Inactive” on second

from the top line for Combustion Air, press the “Save Setting” button once.

If the CPC-3 Display shows the Set Point, Actual Pressure, and Percent Fan Speed in the top line for Draft

or in the second from the top line for Combustion Air, then do NOT press the “Save Setting” button; GO TO

STEP 4.

4) Record the message on the CPC-3 display.

Top Line Reads:

(Disregard if system is for Combustion Air only)

Second from Top Line Reads:

(Disregard if system is for Draft only)

(5) Press the “Increase” button once.

The CPC-3 display will read, "Test Run Off." Press the “Increase” button again if this phrase does not appear on the dis-

play. However, if “Manual Speed Off” is displayed, press the “Decrease” button until “Test Run Off” appears.

(6) Press the “Enter” button once.

The CPC-3 display will read, "Test Run On." Press the “Enter” button again if this phrase does not appear on the dis-

play.

Operation

Mode

Set

Point

Actual

Pressure

% Speed

Operation

Mode

Set

Point

Actual

Pressure

% Speed

Note: The above numbers have no meaning in regards to these steps--

they are merely placeholders. Your numbers do not need to match these.

(7) LED Verification

Indicate the status of the following LEDs located on the CPC-3 by checking the appropriate box within the following

table.

IMPORTANT

If ANY of your indications fall within a shaded box, consult a Tjernlund Products technician at 800-255-4208 or

[email protected].

If NONE of your indications fall within a shaded box, continue on to Section H on page 5.

H. Fan Rotation Testing Determination

IMPORTANT

If operating a SINGLE FAN system, continue on to Section I-1 on page 6.

If operating a MULTIPLE FAN system, continue on to Section I-2 on page 8.

IMPORTANT CPC-3 INDICATORS LIT UNLIT BLINKING

VFD Activated LED (on CPC-3)

Run LED (on VFD)

Alarm LED (on VFD)

CPC-3 and VFD

I-1. Testing Rotation: Single Fan

Press the increase button until the CPC-3 display shows that the fan is running at 50% speed and verify that the

Actual Pressure on the CPC-3 display becomes more negative as the fan speed increases when testing Draft

applications or more positive as the fan speed increases when testing Combustion Air applications.

Wait up to 90 seconds for Actual Pressure to stabilize.

IMPORTANT

If the Actual Pressure DOES NOT become more negative as the fan speed increases toward the 50% speed when

testing Draft applications or more positive when testing Combustion Air applications, continue to Section X-4 on

page 11.

If the Actual Pressure DOES become more negative for Draft applications or most positive for Combustion Air

applications as the fan speed increases, continue.

Record the Actual Pressure

Top Line Reads:

(Disregard if system is for Combustion Air only)

Second from Top Line Reads:

(Disregard if system is for Draft only)

J-1. Dip Switch Adjustment for Proper Fan Rotation

(1) Identify the set of Dip Switches which correspond to the application for which this system

is set up.

If the system is for Draft applications, the following configurations should be made to the set of Dip Switches on the

left side of the CPC-3.

If the system is for Combustion Air applications, the following configurations should be made to the set of Dip

Switches on the right side of the CPC-3.

Operation

Mode

Set

Point

Actual

Pressure

% Speed

Operation

Mode

Set

Point

Actual

Pressure

% Speed

Note: The above numbers have no meaning in regards to these steps--

they are merely placeholders. Your numbers do not need to match these.

(2) Identify the input voltage of the system by looking at the white

label on the VFD.

For 115V

Leave the left Dip Switch (#2) of the appropriate Dip Switch set, as determined

in the previous step, down toward the floor.

Move the right Dip Switch (#1) of the appropriate Dip Switch set, as determined

in the previous step, down toward the floor.

For 230V or 460V

Move the left Dip Switch (#2) of the appropriate Dip Switch set, as determined in

the previous step, up toward the ceiling.

Move the right Dip Switch (#1) of the appropriate Dip Switch set, as determined

in the previous step, down toward the floor.

(3) Wait up to 90 seconds for Actual Pressure to stabilize

(4) Record the Actual Pressure

Top Line Reads:

(Disregard if system is for Combustion Air only)

Second from Top Line Reads:

(Disregard if system is for Draft only)

K-1. Fan Rotation Setting

Compare the last two readings of Actual Pressure recorded on pages 6 and 7.

For a Draft system, identify the more negative Actual Pressure reading and configure the Dip Switches in

the manner that resulted in that more negative Actual Pressure reading.

If more negative reading is the reading recorded on page 6 configure as shown on page 2.

If more negative reading is the reading recorded on page 7 configure as shown on page 7.

For a Combustion Air system, identify the more positive Actual Pressure reading and configure the

Dip Switches in the manner that resulted in that more positive Actual Pressure reading.

If more positive reading is the reading recorded on page 6 configure as shown on page 2.

If more positive reading is the reading recorded on page 7 configure as shown on page 7.

Operation

Mode

Set

Point

Actual

Pressure

% Speed

Operation

Mode

Set

Point

Actual

Pressure

% Speed

Note: The above numbers have no meaning in regards to these steps--

they are merely placeholders. Your numbers do not need to match these.

L-1. Maximum Draft or Combustion Air Verification

Press the “Increase” button until the CPC-3 display shows the fan is running at 100% speed.

Wait up to 90 seconds for Actual Pressure to stabilize.

Record the Actual Pressure

Top Line Reads:

(Disregard if system is for Combustion Air only)

Second from Top Line Reads:

(Disregard if system is for Draft only)

M-1. Ending the System’s Test Mode

Press the “Enter” button once. "Test Run Off" appears on the bottom line of the CPC-3 display. If "Test Run Off" does

not appear press the “Enter” button again.

Press the “Set Up” button once. "Key Pad Open" appears on the bottom line of the CPC-3 display. If "Key Pad Open"

does not appear press the “Set Up” button again.

Press the “Enter” button once. “Lock Out Key Pad” appears on the bottom line of the CPC-3 display. If "Key Pad Open"

does not appear press the “Set Up” button again.

Press the “Save Setting” button once. “Key Pad Locked” appears on the bottom ine of the CPC-3 display. If "Key Pad

Open" does not appear press the “Set Up” button again.

THIS GUIDE IS NOW COMPLETE. CONTINUE TO THE INTERLOCK AND BAFFLE BALANCING

GUIDE TO COMPLETE THE SYSTEM’S START-UP PROCESS.

I-2. Testing Rotation: Multiple Fans

Press the “Increase” button until the CPC-3 displays that the fan is running at 5% speed.

Locate the fan and visually inspect to confirm that the rotation of the impeller for each fan

is rotating in a counter-clockwise manner.

For a VSUB, look at the cooling fan of the impeller which rotates the same

direction as the VSUB impeller.

For a VSAD,look through the discharge grill to inspect the rotation of the

impeller.

NOTE

If at 5% speed you cannot conclusively confirm the rotation of the impeller, powfer down

the fan by switching the roof disconnect switch to the off position. As the fan impeller

slows, visually inspect the fan to confirm the direction of its rotation.

Operation

Mode

Set

Point

Actual

Pressure

% Speed

Operation

Mode

Set

Point

Actual

Pressure

% Speed

Note: The above numbers have no meaning in regards to these steps--

they are merely placeholders. Your numbers do not need to match these.

J-2. Fan Rotation Adjustment

WARNING

REMOVE POWER SOURCE TO THE FAN BEFORE COMPLETING THE FOLLOWING INSTRUCTIONS

UNDER SECTION L-2.

Swap the location of any two motor leads of the fans rotating the wrong direction (clockwise).

The motor leads should be swapped within the 4" x 4" junction box located near the fan.

Repeat this for each fan rotating the incorrect direction.

K-2. Maximum Draft or Combustion Air Verification

Press the “Increase” button until the CPC-3 display shows the fan is running at 100% speed.

Wait up to 90 seconds for Actual Pressure to stabilize.

Record the Actual Pressure

Top Line Reads:

(Disregard if system is for Combustion Air only)

Second from Top Line Reads:

(Disregard if system is for Draft only)

L-2. Ending the System’s Test Mode

Press the “Enter” button once.

"Test Run Off" appears on the bottom line of the CPC-3 display. Press the “Enter” button again if "Test Run Off" does

not appear.

Press the “Set Up” button once.

"Key Pad Open" appears on the bottom line of the CPC-3 display. Press the “Set Up” button again if "Key Pad Open"

does not appear.

THIS GUIDE IS NOW COMPLETE. CONTINUE TO THE INTERLOCK AND BAFFLE BALANCING

GUIDE TO COMPLETE THE SYSTEM’S START-UP PROCESS.

Operation

Mode

Set

Point

Actual

Pressure

% Speed

Operation

Mode

Set

Point

Actual

Pressure

% Speed

Note: The above numbers have no meaning in regards to these steps--

they are merely placeholders. Your numbers do not need to match these.

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