ERV. Energy Recovery Ventilators. Capacity: 400 to 4,000 cfm Model: ERV500i/e, ERV1000i, ERV1500i/e, ERV2000i/e, ERV3000i/e

Transcription

1 ERV Energy Recovery Ventilators Installation, Operation and Maintenance Instructions Manual Capacity: 400 to 4,000 cfm Model: ERV500i/e, ERV1000i, ERV1500i/e, ERV2000i/e, ERV3000i/e 2013 Venmar CES Inc.

2 Table of Contents Nomenclature...3 Safety Considerations...12 General Information...12 Recommended Spare Parts...12 Inspection on Arrival...13 Unit Application Limitations...13 Installation...13 Unit Location Requirements...13 Ceiling Mount (ERV500i, ERV1000i and ERV2000i only)...14 Floor Mount...14 Roofcurbs Supplied by Venmar CES...15 Roofcurbs Supplied by Others...15 Rigging and Lifting the Unit...16 Exhaust Dampers for Indoor Units...16 Field Fabricated Ductwork...16 Hood Installation...17 Access Panel Handles...18 Internal Packaging...18 Coil Piping Connections (ERV3000i/e Only)...18 Condensate Drain Trap (ERV3000i/e Only)...18 Systems Integration...19 Electrical Connections...20 Start-up...21 Pre Start-up Procedure...21 Start-up Procedure...21 Frost Control...23 Sequence of Operation...23 Airflow Balancing...24 Maintenance...24 Air Filters...24 Interior of Unit...25 Fans...26 Enthalpy Wheel...28 Testing and Replacement of the Damper Actuator...30 Coils...31 System Operation Check...31 Appendix A: Roofcurb Detail...32 Appendix B: Dimensional Drawings...36 Appendix C: Rigging Drawing...45 Appendix D: Typical Installations...47 Appendix E: Hood Installation...49 Appendix F: Components...50 Appendix G: Terminal Control Diagrams...55 Appendix H: Troubleshooting...60 Appendix I: Equipment Data...62 Appendix J: Electrical Data...63 Appendix K: Enthalpy Wheel Pressure Drop vs. Flow Formulae and Tables...65 Appendix L: Maintenance Summary Chart...66 Appendix M: ERV Start-up Form and Checklist...67 Appendix N: Effect of Undersized Straight Duct and Elbows on Forward Curved Fans...71 Manufacturer reserves the right to discontinue or change specifications or designs without notice or obligation. VCES-ERV-IOM-4A ERV

3 Nomenclature ERV500i Indoor Unit Nomenclature ( cfm) FROST CONTROL D Recirc defrost 1 E Exhaust only 2 C Non-defrost N Non-defrost, no wall control compatibility 2. VOLTAGE/SPEED A 120/1/60 3. INTERNAL PROTECTION 1 1 insulation, single wall 2 1 insulation, double wall 4. SENSOR CONTACTS W Wheel rotation sensor 3 X No sensor 5. EXTERNAL FINISH S Standard galvanized package W White prepaint package 6. OUTSIDE AIR DAMPER 1 Insulated motorized 2 Insulated spring return 3 No damper 10. ENERGY RECOVERY 1 Aluminum wheel, no purge 9. FREE COOLING S Setpoint enthalpy controller D Differential enthalpy controller T Thermostat (dry bulb) X No free cooling controller 8. FILTRATION S Supply filter E Exhaust filter B Supply and exhaust filters X No filtration 7. EXTERNAL DISCONNECT N Non-fused disconnect switch 4 X No disconnect switch Notes: 1 When ordering recirc defrost, you must order an outside air damper. Recirc defrost option includes recirculation dry contacts for unoccupied mode. 2 Outside air damper required. 3 Units ordered with the wheel rotation sensor option must include a frost control option other than N. 4 Non-fused disconnect switch is field installed. Venmar CES Inc All rights reserved throughout the world. Illustrations cover the general appearance of Venmar CES products at the time of publication and Venmar CES reserves the right to make changes in design and construction at any time without notice. CES Group, LLC d/b/a Venmar CES furnishes equipment pursuant to its then-current Terms and Conditions of Sale and Limited Warranty, copies of which can be found under the Terms & Conditions of Sale and Warranty link at Extended warranties, if any, shall be as offered and acknowledged in writing by Venmar CES. VCES-ERV-IOM-4A ERV

4 ERV500e Outdoor Unit Nomenclature ( cfm) FROST CONTROL E Exhaust only 1 C Non-defrost N Non-defrost, no wall control compatibility 2. VOLTAGE/SPEED B 208/120/1/60 one-speed 2 C 230/120/1/60 one-speed 2 3. INTERNAL PROTECTION 1 1 insulation, single wall 2 1 insulation, double wall 4. SENSOR CONTACTS W Wheel rotation sensor 3 X No contacts, no sensor 5. EXTERNAL FINISH G Grey prepaint package 6. OUTSIDE AIR DAMPER 1 Non-insulated motorized 2 Insulated motorized 3 Insulated spring return 4 No damper 7. EXHAUST AIR DAMPER 1 Backdraft (low leak) 2 Non-insulated motorized (low leak) 3 Insulated motorized (low leak) 4 No damper 14. ENERGY RECOVERY 1 Aluminum wheel, no purge 13. FREE COOLING S Setpoint enthalpy controller D Differential enthalpy controller T Thermostat (dry bulb) X No free cooling controller 12. FILTRATION S Supply filter E Exhaust filter B Supply and exhaust filters X No filtration 11. RETURN AIR B Bottom return air S Side return air 10. SUPPLY DISCHARGE D Down supply discharge E End supply discharge 9. HOODS H Intake/exhaust hoods X No hoods 5 8. EXTERNAL DISCONNECT N Non-fused disconnect switch 4 X No disconnect switch Notes: 1 Outside air damper required. 2 Requires a neutral wire with L1 and L2. 3 Units ordered with the wheel rotation sensor option must include a frost control option other than N. 4 Non-fused disconnect switch is field installed. 5 Must order hoods when ordering dampers. VCES-ERV-IOM-4A ERV

5 ERV1000i Indoor Unit Nomenclature (700 1,381 cfm) FROST CONTROL D Recirc defrost 1 E Exhaust only 2 V VSD frost prevention, no wall control compatibility W VSD frost prevention C Non-defrost N Non-defrost, no wall control compatibility 3 2. VOLTAGE/SPEED A 120/1/60 two-speed 4 B 208/120/1/60 two-speed 4/5 C 230/120/1/60 two-speed 4/5 D 208/3/60 one-speed 4 E 230/3/60 one-speed 4 F 460/3/60 one-speed 4 3. INTERNAL PROTECTION 1 1 insulation, single wall 2 1 insulation, double wall 4. SENSOR CONTACTS D Dirty filter contacts W Wheel rotation sensor 6 B Dirty filter contacts and wheel rotation sensor 6 X No contacts, no sensor 5. EXTERNAL FINISH S Standard galvanized package W White prepaint package 6. OUTSIDE AIR DAMPER 1 Insulated motorized 7 2 Insulated spring return 7 3 Non-insulated motorized 8 4 Non-insulated spring return 8 5 No damper 13. ENERGY RECOVERY 1 Aluminum wheel, no purge 2 Aluminum wheel c/w purge 12. CASSETTE ACCESS R Reverse cassette access S Standard cassette access 11. LOW SPEED L Reduced low speed N Normal low speed X No low speed 10. FREE COOLING S Setpoint for enthalpy controller D Differential enthalpy controller T Thermostat (dry bulb) X No free cooling controller 9. FILTRATION S Supply filter E Exhaust filter B Supply and exhaust filters X No filtration 8. EXTERNAL DISCONNECT F Fused disconnect switch 9 N Non-fused disconnect switch 9 X No disconnect switch 7. DOOR FASTENERS S Standard filter door c/w screws D Deluxe filter door c/w quarter turn fasteners Notes: 1 When ordering recirc defrost, you must order an insulated outside air damper. Recirc defrost option includes recirculation dry contacts for unoccupied mode. Includes exhaust backdraft. 2 Outside air damper required. 3 No damper required. 4 Single-phase motors are available with low speed options L or N. Three-phase motors are only available with low speed option X. 5 Requires a neutral wire with L1 and L2. 6 Units ordered with the wheel rotation sensor option must include a frost control option other than V or N. 7 This option is for recirc defrost units only. 8 This option cannot be ordered on recirc defrost units. 9 Fused/non-fused disconnect switch is field installed. VCES-ERV-IOM-4A ERV

6 ERV1500i Indoor Unit Nomenclature (800 2,000 cfm) FROST CONTROL D Recirc defrost 1 E Exhaust only 2 V VSD frost prevention, no wall control compatibility W VSD frost prevention M Pre-heat 8 kw, two-stage 3 O Pre-heat 8 kw, four-stage 3 P Pre-heat 8 kw, SCR 3 Q Pre-heat 14 kw, two-stage 3 R Pre-heat 14 kw, four-stage 3 S Pre-heat 14 kw, SCR 3 T Pre-heat 20 kw, two-stage 3 U Pre-heat 20 kw, four-stage 3 Y Pre-heat 20 kw, SCR 3 C Non-defrost N Non-defrost, no wall control compatibility 4 2. VOLTAGE/SPEED A 120/1/60 one-speed B 208/120/1/60 one-speed 5 C 230/120/1/60 one-speed 5 D 208/3/60 one-speed E 230/3/60 one-speed F 460/3/60 one-speed G 575/3/60 one-speed H 208/120/1/60 two-speed 5 I 230/120/1/60 two-speed 5 N 208/3/60 VFD 6 O 230/3/60 VFD 6 P 460/3/60 VFD 6 Q 575/3/60 VFD 6 3. INTERNAL PROTECTION 1 1 insulation, single wall 2 1 insulation, double wall 4. SENSOR CONTACTS D Dirty filter contacts W Wheel rotation sensor 7 B Dirty filter contacts and wheel rotation sensor 7 X No contacts, no sensor 5. EXTERNAL FINISH S Standard galvanized package W White prepaint package 6. OUTSIDE AIR DAMPER 1 Insulated motorized 2 Insulated spring return 3 No damper 15. ENERGY RECOVERY 1 Aluminum wheel, no purge 2 Aluminum wheel c/w purge 14. FREE COOLING S Setpoint enthalpy controller D Differential enthalpy controller T Thermostat (dry bulb) X No free cooling controller 13. FILTRATION S Supply filter E Exhaust filter B Supply and exhaust filters X No filtration 12. RETURN AIR B Bottom return air E End return air T Top return air 11. SUPPLY DISCHARGE D Down supply discharge E End supply discharge T Top supply discharge 10. EXHAUST DISCHARGE E End exhaust discharge T Top exhaust discharge S Side exhaust discharge 9. EXTERNAL DISCONNECT F Fused disconnect switch 9 N Non-fused disconnect switch 9 X No disconnect switch 8. DOOR FASTENERS S Standard blower door and filter door c/w metal handles and screws D Deluxe blower door and filter door c/w polyamide handles and quarter turn fasteners 7. EXHAUST AIR DAMPER 8 1 Backdraft (low leak) 2 Non-insulated motorized (low leak) 3 Insulated motorized (low leak) 4 No damper Notes: 1 When ordering recirc defrost, you must order outside air and exhaust air dampers. Recirc defrost option includes recirculation dry contacts for unoccupied mode. 2 Outside air damper required /1/60, 208/1/60 and 230/1/60 voltages are not available with pre-heat frost control options. 4 No dampers required. 5 Requires a neutral wire with L1 and L2. 6 All VFD options include one controller per motor. 7 Units ordered with the wheel rotation sensor option must include a frost control option other than V or N. 8 Exhaust air damper must be field installed in exhaust duct. 9 Fused/non-fused disconnect switch is field installed. VCES-ERV-IOM-4A ERV

7 ERV1500e Outdoor Unit Nomenclature (800 2,000 cfm) FROST CONTROL D Recirc defrost 1 E Exhaust only 2 V VSD frost prevention, no wall control compatibility W VSD frost prevention M Pre-heat 8 kw, two-stage 3 O Pre-heat 8 kw, four-stage 3 P Pre-heat 8 kw, SCR 3 Q Pre-heat 14 kw, two-stage 3 R Pre-heat 14 kw, four-stage 3 S Pre-heat 14 kw, SCR 3 T Pre-heat 20 kw, two-stage 3 U Pre-heat 20 kw, four-stage 3 Y Pre-heat 20 kw, SCR 3 C Non-defrost N Non-defrost, no wall control compatibility 4 2. VOLTAGE/SPEED A 120/1/60 one-speed B 208/120/1/60 one-speed 5 C 230/120/1/60 one-speed 5 D 208/3/60 one-speed E 230/3/60 one-speed F 460/3/60 one-speed G 575/3/60 one-speed H 208/120/1/60 two-speed 5 I 230/120/1/60 two-speed 5 N 208/3/60 VFD 6 O 230/3/60 VFD 6 P 460/3/60 VFD 6 Q 575/3/60 VFD 6 3. INTERNAL PROTECTION 1 1 insulation, single wall 2 1 insulation, double wall 4. SENSOR CONTACTS D Dirty filter contacts W Wheel rotation sensor 7 B Dirty filter contacts and wheel rotation sensor 7 X No contacts, no sensor 5. EXTERNAL FINISH G Grey prepaint package 15. ENERGY RECOVERY 1 Aluminum wheel, no purge 2 Aluminum wheel c/w purge 14. FREE COOLING S Setpoint enthalpy controller D Differential enthalpy controller T Thermostat (dry bulb) X No free cooling controller 13. FILTRATION S Supply filter E Exhaust filter B Supply and exhaust filters X No filtration 12. RETURN AIR B Bottom return air E End return air 11. SUPPLY DISCHARGE D Down supply discharge E End supply discharge 10. HOODS H Intake/exhaust hoods X No hoods 9 9. EXTERNAL DISCONNECT F Fused disconnect switch 8 N Non-fused disconnect switch 8 X No disconnect switch 8. DOOR FASTENERS S Standard blower door and filter door c/w metal handles and screws D Deluxe blower door and filter door c/w polyamide handles and quarter turn fasteners 7. EXHAUST AIR DAMPER 1 Backdraft (low leak) 2 Non-insulated motorized (low leak) 3 Insulated motorized (low leak) 4 No damper 6. OUTSIDE AIR DAMPER 1 Insulated motorized 2 Insulated spring return 3 No damper Notes: 1 When ordering recirc defrost, you must order outside air and exhaust air dampers. Recirc defrost option includes recirculation dry contacts for unoccupied mode. 2 Outside air damper required /1/60 and 230/1/60 voltages are not available with pre-heat frost control options. 4 No dampers required. 5 Requires a neutral wire with L1 and L2. 6 All VFD options include one controller per motor. 7 Units ordered with the wheel rotation sensor option must include a frost control option other than V or N. 8 Fused/non-fused disconnect switch is field installed. 9 Must order hoods when ordering dampers. VCES-ERV-IOM-4A ERV

8 ERV2000i Indoor Unit Nomenclature (1,200 2,800 cfm) FROST CONTROL D Recirc defrost 1 E Exhaust only 2 V VSD frost prevention, no wall control compatibility W VSD frost prevention C Non-defrost N Non-defrost, no wall control compatibility 3 2. VOLTAGE/SPEED B 208/120/1/60 one-speed 4 C 230/120/1/60 one-speed 4 D 208/3/60 one-speed E 230/3/60 one-speed F 460/3/60 one-speed G 575/3/60 one-speed N 208/3/60 VFD 9/10 O 230/3/60 VFD 9/10 P 460/3/60 VFD 9/10 3. INTERNAL PROTECTION 1 1 insulation, single wall 2 1 insulation, double wall 4. SENSOR CONTACTS D Dirty filter contacts W Wheel rotation sensor 5 B Dirty filter contacts and wheel rotation sensor 5 X No contacts, no sensor 5. EXTERNAL FINISH S Standard galvanized package W White prepaint package 12. ENERGY RECOVERY 1 Aluminum, no purge 2 Aluminum wheel c/w purge 11. CASSETTE ACCESS R Reverse cassette access S Standard cassette access 10. FREE COOLING S Setpoint enthalpy controller D Differential enthalpy controller T Thermostat (dry bulb) X No free cooling controller 9. FILTRATION S Supply filter E Exhaust filter B Supply and exhaust filters X No filtration 8. EXTERNAL DISCONNECT F Fused disconnect switch 8 N Non-fused disconnect switch 8 X No disconnect switch 7. DOOR FASTENERS S Standard filter door c/w screws D Deluxe filter door c/w quarter turn fasteners 6. OUTSIDE AIR DAMPER 1 Insulated motorized 6 2 Insulated spring return 6 3 Non-insulated motorized 7 4 Non-insulated spring return 7 5 No damper Notes: 1 When ordering recirc defrost, you must order outside air and exhaust air dampers. Recirc defrost option includes recirculation dry contacts for unoccupied mode. Includes exhaust backdraft. 2 Outside air damper required. 3 No dampers required. 4 Requires a neutral wire with L1 and L2. 5 Units ordered with the wheel rotation sensor option must include a frost option other than V or N. 6 This option is for recirc defrost units only. 7 This option cannot be ordered on recirc defrost units. 8 Fused/non-fused disconnect switch is field installed. 9 All VFD options include one controller per motor. 10 Minimum motor size is 1 hp. VCES-ERV-IOM-4A ERV

9 ERV2000e Outdoor Unit Nomenclature (1,200 2,800 cfm) FROST CONTROL D Recirc defrost 1 E Exhaust only 2 V VSD frost prevention, no wall control compatibility W VSD frost prevention C Non-defrost N Non-defrost, no wall control compatibility 2. VOLTAGE/SPEED B 208/120/1/60 one-speed 4 C 230/120/1/60 one-speed 4 D 208/3/60 one-speed E 230/3/60 one-speed F 460/3/60 one-speed G 575/3/60 one-speed N 208/3/60 VFD 8/9/10 O 230/3/60 VFD 8/9/10 P 460/3/60 VFD 8/9/10 3. INTERNAL PROTECTION 1 1 insulation, single wall 2 1 insulation, double wall 4. SENSOR CONTACTS D Dirty filter contacts W Wheel rotation sensor 5 B Dirty filter contacts and wheel rotation sensor 5 X No contacts, no sensor 5. EXTERNAL FINISH G Grey prepaint package 6. OUTSIDE AIR DAMPER 1 Non-insulated motorized (low leak) 2 Insulated motorized (low leak) 3 Insulated spring return (low leak) 4 No damper 7. EXHAUST AIR DAMPER 1 Backdraft (low leak) 2 Non-insulated motorized (low leak) 3 Insulated motorized (low leak) 4 No damper 15. ENERGY RECOVERY 1 Aluminum wheel, no purge 2 Aluminum wheel c/w purge 14. FREE COOLING S Setpoint enthalpy controller D Differential enthalpy controller T Thermostat (dry bulb) X No free cooling controller 13. FILTRATION S Supply filter E Exhaust filter B Supply and exhaust filters X No filtration 12. RETURN AIR B Bottom return air E End return air 11. SUPPLY DISCHARGE D Down supply discharge E End supply discharge 10. HOODS H Intake/exhaust hoods X No hoods 7 9. EXTERNAL DISCONNECT F Fused disconnect switch 6 N Non-fused disconnect switch 6 X No disconnect switch 8. DOOR FASTENERS S Standard blower door and filter door c/w metal handles and screws D Deluxe blower door and filter door c/w polyamide handles and quarter turn fasteners Notes: 1 When ordering recirc defrost, you must order outside air and exhaust air dampers. Recirc defrost option includes recirculation dry contacts for unoccupied mode. 2 Outside air damper required. 3 No dampers required. 4 Requires a neutral wire with L1 and L2. 5 Units ordered with the wheel rotation sensor option must include a frost control option other than V or N. 6 Fused/non-fused disconnect switch is field installed. 7 Must order hoods when ordering dampers. 8 All VFD options include one controller per motor. 9 Minimum motor size 1 hp. 10 For selection below 22ºF [ 30ºC], please consult factory. VCES-ERV-IOM-4A ERV

10 ERV3000i Indoor Unit Nomenclature (2,000 4,000) FROST CONTROL D Recirc defrost 1 E Exhaust only 2 V VSD frost prevention, no wall control compatibility W VSD frost prevention M Pre-heat 20 kw, two-stage 3 O Pre-heat 20 kw, four-stage 3 P Pre-heat 20 kw, SCR 3 Q Pre-heat 30 kw, two-stage 3 R Pre-heat 30 kw, four-stage 3 S Pre-heat 30 kw, SCR 3 T Pre-heat 40 kw, two-stage 3 U Pre-heat 40 kw, four-stage 3 Y Pre-heat 40 kw, SCR 3 A Pre-heat w/ unocc. recirc 20 kw, two-stage 1/3/4 B Pre-heat w/ unocc. recirc 20 kw, four-stage 1/3/4 F Pre-heat w/ unocc. recirc 20 kw, SCR 1/3/4 G Pre-heat w/ unocc. recirc 30 kw, two-stage 1/3/4 H Pre-heat w/ unocc. recirc 30 kw, four-stage 1/3/4 I Pre-heat w/ unocc. recirc 30 kw, SCR 1/3/4 J Pre-heat w/ unocc. recirc 40 kw, two-stage 1/3/4 K Pre-heat w/ unocc. recirc 40 kw, four-stage 1/3/4 L Pre-heat w/ unocc. recirc 40 kw, SCR 1/3/4 C Non-defrost N Non-defrost, no wall control compatibility 5 2. VOLTAGE/SPEED B 208/120/1/60 one-speed 6 C 230/120/1/60 one-speed 6 D 208/3/60 one-speed E 230/3/60 one-speed F 460/3/60 one-speed G 575/3/60 one-speed H 208/120/1/60 two-speed 6 I 230/120/1/60 two-speed 6 N 208/3/60 VFD 7 O 230/3/60 VFD 7 P 460/3/60 VFD 7 Q 575/3/60 VFD 7 3. INTERNAL PROTECTION 1 1 insulation, single wall 2 1 insulation, double wall 4. SENSOR CONTACTS D Dirty filter contacts W Wheel rotation sensor 8 B Dirty filter contacts and wheel rotation sensor 8 X No contacts, no sensor 5. EXTERNAL FINISH S Standard galvanized package W White prepaint package 6. OUTSIDE AIR DAMPER 1 Non-insulated motorized (low leak) 2 Insulated motorized (low leak) 3 Insulated spring return (low leak) 4 No damper 20. COOLING C Chilled water 11 D Dx cooling 11 X No cooling 19. HEATING H Hot water S Steam heat X No heat 18. ENERGY RECOVERY 1 Aluminum wheel, no purge 2 Aluminum wheel c/w purge 17. BLOWER ISOLATION R Rubber blower isolation S Spring blower isolation 16. FREE COOLING S Setpoint enthalpy controller D Differential enthalpy controller T Thermostat (dry bulb) X No free cooling controller 15. HEF FILTRATION H High efficiency supply filter X No HEF filtration 14. MEF FILTRATION S MEF supply filter E MEF exhaust filter B MEF supply and exhaust filters X No MEF filtration 13. RETURN AIR B Bottom return air E End return air T Top return air 12. SUPPLY DISCHARGE D Down supply discharge E End supply discharge T Top supply discharge 11. EXHAUST DISCHARGE E End exhaust discharge S Side exhaust discharge T Top exhaust discharge 10. OUTSIDE AIR INTAKE E End outside air intake T Top outside air intake S Side outside air intake 9. EXTERNAL DISCONNECT F Fused disconnect switch 10 N Non-fused disconnect switch 10 X No disconnect switch 8. DOOR FASTENERS S Standard blower door and filter door c/w metal handles and screws D Deluxe blower door and filter door c/w polyamide handles and quarter turn fasteners 7. EXHAUST AIR DAMPER 9 1 Backdraft (low leak) 2 Non-insulated motorized (low leak) 3 Insulated motorized (low leak) 4 No damper Notes: 1 When ordering recirc defrost or unoccupied recirc, you must order outside air and exhaust air dampers. Recirc defrost option includes recirculation dry contacts for unoccupied mode. 2 Outside air damper required /1/60 and 230/1/60 voltages are not available with pre-heat frost control options. 30 and 40 kw pre-heat frost control options are not available with 208/230/3/60 voltages. 4 Unoccupied recirc is not available with side outside air intake option. 5 No dampers required. 6 Requires a neutral wire with L1 and L2. 7 All VFD options include one controller per motor. 8 Units ordered with the wheel rotation sensor option must include a frost control option other than V or N. 9 Exhaust air damper is supplied loose and must be field installed in exhaust duct. 10 Fused/non-fused disconnect switch is field installed. 11 A maximum of 2,650 cfm is allowed for cooling applications. VCES-ERV-IOM-4A ERV

11 ERV3000e Outdoor Unit Nomenclature (2,000 4,000) FROST CONTROL D Recirc defrost 1 E Exhaust only 2 V VSD frost prevention no wall control compatibility W VSD frost prevention M Pre-heat 20 kw, two-stage 3 O Pre-heat 20 kw, four-stage 3 P Pre-heat 20 kw, SCR 3 Q Pre-heat 30 kw, two-stage 3/4 R Pre-heat 30 kw, four-stage 3/4 S Pre-heat 30 kw, SCR 3/4 T Pre-heat 40 kw, two-stage 3/4 U Pre-heat 40 kw, four-stage 3/4 Y Pre-heat 40 kw, SCR 3/4 C Non-defrost N Non-defrost, no wall control compatibility 5 2. VOLTAGE/SPEED B 208/120/1/60 one-speed 6 C 230/120/1/60 one-speed 6 D 208/3/60 one-speed E 230/3/60 one-speed F 460/3/60 one-speed G 575/3/60 one-speed H 208/120/3/60 two-speed 6 I 230/120/1/60 two-speed 6 N 208/3/60 VFD 7 O 230/3/60 VFD 7 P 460/3/60 VFD 7 Q 575/3/60 VFD 7 3. INTERNAL PROTECTION 1 1 insulation, single wall 2 1 insulation, double wall 4. SENSOR CONTACTS D Dirty filter contacts W Wheel rotation sensor 8 B Dirty filter contacts and wheel rotation sensor 8 X No contacts, no sensor 5. EXTERNAL FINISH G Grey prepaint package 6. OUTSIDE AIR DAMPER 1 Non-insulated motorized (low leak) 2 Insulated motorized (low leak) 3 Insulated spring return (low leak) 4 No damper 7. EXHAUST AIR DAMPER 1 Backdraft (low leak) 2 Non-insulated motorized (low leak) 3 Insulated motorized (low leak) 4 No damper 19. COOLING C Chilled water 11 D Dx cooling 11 X No cooling 18. HEATING H Hot water S Steam heat X No heat 17. ENERGY RECOVERY 1 Aluminum wheel, no purge 2 Aluminum wheel c/w purge 16. BLOWER ISOLATION R Rubber blower isolation S Spring blower isolation 15. FREE COOLING S Setpoint enthalpy controller D Differential enthalpy controller T Thermostat (dry bulb) X No free cooling controller 14. HEF FILTRATION H High efficiency supply filter X No HEF filtration 13. MEF FILTRATION S MEF supply filter E MEF exhaust filter B MEF supply and exhaust filters X No MEF filtration 12. RETURN AIR B Bottom return air E End return air 11. SUPPLY DISCHARGE D Down supply discharge E End supply discharge 10. HOODS H Intake/exhaust hoods X No hoods EXTERNAL DISCONNECT F Fused disconnect switch 9 N Non-fused disconnect switch 9 X No disconnect switch 8. DOOR FASTENERS S Standard blower door and filter door c/w metal handles and screws D Deluxe blower door and filter door c/w polyamide handles and quarter turn fasteners Notes: 1 When ordering recirc defrost, you must order outside air and exhaust air dampers. Recirc defrost option includes recirculation dry contacts for unoccupied mode. 2 Outside air damper required /1/60 and 230/1/60 voltages are not available with preheat frost control options and 40 kw pre-heat frost control options are not available with 208/230/3/60 voltages. 5 No dampers required. 6 Requires a neutral wire with L1 and L2. 7 All VFD options include one controller per motor. 8 Units ordered with the wheel rotation sensor option must include a frost control option other than V or N. 9 Fused/non-fused disconnect switch is field installed. 10 Must order hoods when ordering dampers. 11 A maximum of 2,650 cfm is allowed for cooling applications. VCES-ERV-IOM-4A ERV

12 Safety Considerations Warning, Caution and Important notes appear throughout this manual in specific and appropriate locations to alert Installing Contractors and maintenance or service personnel of potential safety hazards, possible equipment damage or to alert personnel of special procedures or instructions that must be followed as outlined below.! WARNING Identifies an instruction which, if not followed, might cause serious personal injuries including possibility of death. CAUTION Identifies an instruction which, if not followed, might severely damage the unit, its components, the assembly or final installation. IMPORTANT Indicates supplementary information needed to fully complete an instruction or installation. Hazards may exist within this equipment because it contains electrical and powerful moving components. Only qualified service personnel should install or service this equipment. Untrained personnel can perform basic maintenance such as maintaining filters. Observe precautions marked in literature and on labels attached to the unit. Follow all safety codes.! WARNING Disconnect the main power switch to the unit before performing service or maintenance. Electric shock can cause personal injury or death. General Information This manual is designed to provide general information on the common operation of all standard and optional components that may have been installed in the unit. Note that some sections of this manual may not apply to your unit. This manual has been designed for general purpose and describes options offered by Venmar CES that could be included in the unit. Consult the manual from the component Manufacturer if more detailed technical information about a specific component is required. Instructions on certain options such as VFDs, enthalpy controllers and electric pre-heat coils which are factory installed are placed inside a Ziploc bag along with the IOM and located inside the unit. Instructions for accessory items which are shipped loose for field installation are included with the item. The electrical schematic is attached to the inside of the control panel. Recommended Spare Parts Spare parts should be ordered at the time the installation is accepted by the Owner. Spare parts will reduce the down time in the event of a failure. The list of spare parts outlined below is considered minimal. Installation in remote locations or when the operation of heating equipment is essential may require more spare parts than listed. Please contact the service department at Venmar CES for recommendations. Minimum spare parts include: Two sets of fuses One matching set of fan belts One set of filters VCES-ERV-IOM-4A ERV

13 Inspection on Arrival Inspect the equipment exterior and interior for any damage on arrival that may have occurred during unit shipment and for shipped loose parts. Ensure that there is no damage to any protruding exterior components or to internal components such as fans, motors, dampers, enthalpy wheel and structures. File a claim with the shipping company if the unit is damaged. Check the packing slip against all items received. If any items are missing, sign the carrier s bill of lading with the notation Shipment Received Less Item #. Contact the factory immediately if damage is found. No return shipment will be accepted without authorization. IMPORTANT The hoods for outdoor units are not installed from the factory for shipping purposes and must be installed on site. Hoods can be installed prior to rigging the unit or after the unit is installed. See Rigging and Lifting the Unit. IMPORTANT The exhaust dampers for indoor units (if ordered) are not installed from the factory and must be installed on site. See Exhaust Dampers for Indoor Units. Unit Application Limitations! WARNING Venmar CES equipment is not designed to be used for temporary heating, cooling and/or ventilation during construction. Using Venmar CES units for temporary ventilation during construction is subject to the unit warranty terms and should be reviewed carefully before proceeding, as this may void the standard warranty conditions. Fine dust, larger particulate matter, solvents, varnishes and other chemicals may cause filter clogging and elevated cabinet pressures, higher power consumption and possible irreparable damage to the desiccant material of the enthalpy wheel, which could reduce energy recovery performance of the wheel and also reduce the heat transfer effectiveness of other components. Potential damages include, but are not limited to, these examples. Installation Unit Location Requirements Consult local building codes and electrical codes for special installation requirements and note additional requirements listed in this manual. In choosing the installation location of the unit, consider the following factors: The unit should be installed to allow easy access for maintenance and for systems operation. See Appendix B for dimensions and recommended service and maintenance clearances. Additional installation clearances on indoor unit are provided in Appendix D. When possible, mount the unit over an unused area such as a hallway. Although fans and motors are mounted on vibration pads or isolators and are dynamically balanced, the unit will be even less perceptible if positioned away from busy offices. Locate the unit in an area requiring the least amount of ductwork and directional changes to allow optimum performance, to reduce pressure loss and to use less electricity to achieve proper ventilation. Ductwork must be in accordance with ducting mechanical rules to prevent sound issues and system effects. In cold climates with 5 F [ 20 C] design, an indoor unit must be mounted in a dry area (not exceeding 30% RH) to avoid water condensation on the cabinet during winter operation. Alternatively, accommodation must be made for condensation on the cabinet exterior. Do not mount units in an area where exposure to electrical panels or other hazards will occur. On indoor units, a mounting location close to an exterior partition will minimize the length of insulated ductwork required. Appendix D illustrates ductwork through exterior partitions. These should be separated by a minimum of 10 feet [3,000 mm] for Class 2 exhaust or as required by ASHRAE 62.1 to avoid outside cross contamination. The fresh air intake hood must be positioned away from sources of contamination such as hot chimneys or kitchen exhaust vents. Fresh air intake must also be positioned in a direction opposite to that of prevailing winds to reduce entry of snow or rain. The unit should be mounted on a level foundation to allow condensation to flow into internal drains (when provided). The foundation must provide adequate continuous support to minimize deflection of the unit base frame to not more than 1/16 [1.6 mm] over VCES-ERV-IOM-4A ERV

14 entire length. In addition to these recommendations, a Structural Engineer must be involved to properly size supporting structural elements. When mounting the unit indoors and drain connections are required, mount the unit on a housekeeping pad of sufficient height to allow for drain trap height and condensate lines to slope toward the building drain. Install condensate pumps to reduce height of housekeeping pads or drill holes in the concrete pad or mechanical room floor for sufficient trap height. When mounting the unit on a roofcurb check the height from the finished roof to the bottom of the intake hood. Consult with Local Authorities or your building code for minimal intake hood height for the water-tight height from and above the finished roof and in snow prone areas the buildup of snow to determine the height of the roofcurb. If additional height is required from the finished roof to the top of the roofcurb, to the bottom of the intake hood or if other than level, custom height roofcurbs must be ordered. When mounting the unit on the roof, check for possibility of exhaust re-entrainment which can be caused by placing the unit in an equipment well or within a recirculation zone created by the interaction of the wind and resistance of the building, in which case extension of the exhaust discharge or outdoor intake may be required. Ceiling Mount (ERV500i, ERV1000i and ERV2000i only) The unit must be mounted level and may be hung with threaded rod (field supplied) through the protruding frame at the base of the unit. Hole centers are shown in the overall dimensional drawings in Appendix B. Do not block access to panels as indicated in Appendix D. Rubber or seismic vibration isolation may be required in some regions (field supplied and specified). IMPORTANT The Manufacturer recommends that the ERV1500i and ERV3000i be floor mounted only. The unit may be secured to the floor using isolation/vibration pads. The pads may be located on each corner of the unit s frame (all mounting hardware is field supplied and specified). Floor Mount VCES-ERV-IOM-4A ERV

15 Roofcurbs Supplied by Venmar CES Roofcurbs supplied by Venmar CES should be mounted as follows: The roofcurb is shipped knocked-down with assembly hardware and instructions provided. The roofcurb must be field erected, assembled and set in place by the Installing Contractor. Roofcurb dimensions are submitted with the unit mechanical drawings which can also be found in Appendix A and Appendix B which include clearances and weights. Outdoor air intake, supply discharge, return air inlet and exhaust air discharge opening locations are identified in the equipment submittals or where alternative locations are available from the nomenclature in the submittals or on the unit nameplate. After the roofcurb has been assembled, ensure that the roofcurb dimensions suit the unit for which it is designated. The cross members must be positioned as per the roofcurb drawing to properly support the ductwork plenums for bottom vertical return and supply connections and for stability. Ensure that the assembled roofcurb is square, plumb and level to within 1/16 [1.6 mm] over the entire length. The building structure must provide continuous structural support to the full perimeter of the roofcurb and may be shimmed. The roofcurb must be fastened to the building structure. The Installing Contractor is responsible for making the roofcurb water-tight by caulking all roofcurb joints. IMPORTANT The following items must be completed prior to setting the unit on the roofcurb: The roofcurb roofing must be completed including insulation, cant strip, flashing and counter-flashing. Vertical ductwork must be attached to the roofcurb and building structure, not to the unit. The ductwork can be flanged over at the top of the perimeter opening cross members and/or curb for an air-tight seal. See Appendix A for information on roofcurb, installation and dimensions. If there is no building roof access underneath the unit and drain or piping connections must be made (in the roofing), it is recommended to do so before unit installation using the appropriate materials provided by the Installing Contractor. Remove the length of 3/8 [9.5 mm] polyvinyl gasket strip with adhesive backing supplied with the roofcurb and apply a continuous strip to the top perimeter of the roofcurb and ductwork opening flanges/cross members for an air- and water-tight seal as shown in Appendix A. IMPORTANT The gasket between the unit and the roofcurb is critical for an air- and water-tight seal. An improperly applied gasket can result in air and water leakage and poor unit performance. Position the unit with equal spacing all around between the roofcurb and inside unit base rail as it is being lowered. Roofcurbs Supplied by Others Roofcurbs supplied by others must be designed with the same dimensions and cross member arrangement as per Venmar CES roofcurb drawings and must be designed to evenly withstand perimeter and cross section static loads. IMPORTANT Venmar CES is not liable for any damages, costs or other issues arising from roofcurbs supplied by others. VCES-ERV-IOM-4A ERV

16 Rigging and Lifting the Unit IMPORTANT The hoods for these units are not installed from the factory and must be installed on site. They can be installed prior to rigging the unit or after the unit is installed. Hoods are shipped on top of the unit. When rigging the unit, make certain that the hoods are secured and are not damaged by the spreader bars. See Appendix E for hood installation. Unit shall be lifted by cables attached to all the lifting points provided on the unit base as shown in Appendix C. For the ERV500e, a field supplied support beam such as a C channel is required under and attached to the base as shown in Figure C1. When lifting the unit use spreader bars and cables to prevent damage to the unit casing. Provide additional blocking and coverings (as required) to prevent damage to the unit finish and/or components. The spreader bars will help to maintain a certain distance between the cables and the unit. Venmar CES will not be responsible for any damage caused to the unit casing during the lifting process. The lifting point must be at the center of gravity to ensure that the unit is level during hoisting and prior to setting. When commencing to hoist, take up the slack in the hoisting cables slowly and gradually increase the cable tension until the full unit weight is suspended. Avoid sudden, jerking movements. Do not permit the unit to be suspended by the lifting lugs for an extended period of time. CAUTION All panels must be in place when rigging. Exhaust Dampers for Indoor Units The exhaust dampers for indoor units (if ordered) are not installed from the factory and must be be installed and wired (if required) on site. Coiled 24V wire harness with plug connector is provided on the unit for motorized dampers when ordered. The dampers should be mounted sufficiently far enough downstream from the exhaust fan discharge to avoid causing deficient fan performance or added pressure loss. A gradual transition in the duct from discharge to damper size is recommended. Dampers are for in-duct mounting; see Appendix I for damper dimensions and Field Fabricated Ductwork for fan outlet duct considerations. Field Fabricated Ductwork On outdoor units with bottom vertical duct connections, secure all ducts to the roofcurb and building structure prior to unit installation. See Roofcurbs Supplied by Venmar CES. Do not secure ductwork to the unit. On other duct connection locations, make connections to the casing by applying caulking around the connection and screwing flanged ducts directly to the casing and/or flange with self-drilling sheet metal screws. It is important to seal all duct connections to prevent air leakage and system performance problems. Ductwork must be supported by the building structure. For unit and duct opening sizes refer to submittal documents or see Appendix B. IMPORTANT Ensure that the fasteners used to make duct connections do not interfere with fans or dampers in the unit. Transitions may be required to make connection with ductwork that is properly sized for minimum noise and pressure loss as shown in Appendix D. airflows on units with direct driven fans (ERV500i/e and ERV1000i) as shown in Appendix D. Electric pre-heat in the outdoor air duct, if used as frost prevention on indoor units, must be installed at a minimum distance from the unit of 24 [610 mm] as shown in Appendix D. Insulate and weatherproof all external ductwork, joints and roof openings with counter-flashing and mastic in accordance with applicable codes. Ductwork running through roof decks must comply with local fire codes. Both duct connections to outside must be insulated to avoid condensation and heat loss. Ducts passing through unconditioned spaces must be insulated and covered with a vapor barrier. Flexible connectors should be installed close to the unit in the duct leading to occupied spaces to minimize noise transmission. Airflow rate balancing dampers are recommended for both supply and exhaust ducts to allow for adjustment of VCES-ERV-IOM-4A ERV

17 Duct Design Considerations The discharge ductwork immediately downstream from the double width double inlet fan is critical for successful applications. Poorly designed ductwork can degrade fan performance and contribute to excessive pressure drop and noise. When designing ductwork in the field, it is important to use a straight discharge duct of the same dimension as the fan outlet connection to obtain maximum fan performance. The straight section of ductwork helps the airflow to develop a uniform velocity profile as it exits the fan and allows the velocity pressure to recover into static pressure. See Figure 1. Centrifugal fan Cutoff Figure 1: Duct design Discharge duct 100% effective duct length 2½ diameters at 2,500 FPM For 100% recovery of velocity pressure into static pressure, the straight portion of the discharge duct must be at least 2.5 times the Equivalent Duct Diameter of the rectangular duct connection up to 2,500 fpm outlet velocity or less. Add one duct diameter for each additional 1,000 fpm outlet velocity to the length of the straight portion of discharge duct. The equivalent duct diameter is equal to square root of (4ab Pi) where a and b are the rectangular dimensions of the fan discharge opening. Refer to Appendix N to determine the effect of undersized straight sections of duct with or without duct elbows within the 100% minimum effective duct length (reference: AMCA publication 201, Fans and Systems). Example: For an ERV1500e with a supply flow rate of 2,000 cfm, with a bottom supply fan discharge connection, with rectangular connection of a = 9.25 and b = the length of straight duct is 17 before entering a 90 degree elbow is reached in position C as shown in Figure N1: The equivalent duct diameter is equal to square root of (4*9.25*10.25 Pi) = The outlet velocity is equal to 2,000 cfm/(9.25*10.25/144) = 3,028 fpm Therefore the minimum length of straight for 100% effective recovery needed would be equal to *(2.5+(3,028 2,500)/1,000) = 34 rounded up to the next whole inch The effective straight duct was 17 long or 17/34 *100 = 50% effective From Appendix I, the ERV500 and ERV1000 have SWSI fans; all other models have DWDI fans. Using Table N1, with elbow position C and 50% duct effective length, use curve S From Figure N2, with an S curve at 3,028 fpm and 1.0 multiplier for DWDI fans the added external pressure drop is approximately 0.47*1.00 = 0.47 w.c. which must be added to the external pressure drop for the unit Hood Installation Intake and exhaust hoods for these models are shipped separately from the unit. To install hoods see Appendix E. A quick connect for the damper motors is provided to connect to the main body of the unit. Make sure that all screws are secured to maintain proper support and keep seals water-tight. VCES-ERV-IOM-4A ERV

18 IMPORTANT Securing door fasteners too tightly has negative effects on the door gasket and should be avoided. Handles for access panels are provided but must be installed on site. Handles and fasteners are secured inside or on top (indoor unit) of the unit. Remove from packaging and install according to Figure 2. Access Panel Handles Access panel Metal or polyamide handle Figure 2: Access panel #10 x ¾ Screw Internal Packaging Remove access panels and all packaging from the unit. Note that there is packaging for wheel support during shipping (ERV2000i/e only, see Figure 6). Removal of all packaging is critical. CAUTION Remove all ERV wheel packaging prior to start-up. Coil Piping Connections (ERV3000i/e Only) Integrated heating and cooling coil options are only available on the ERV3000i/e models. Cooling coils are limited to airflows up to 2,650 cfm to limit maximum coil velocity to 505 fpm. All heating and cooling configurations are factory mounted with cooling coil upstream, heating coil directly downstream (when both required). Coil connections are extended outside on the side of the cabinet. External supply and return piping design and all other safety, freeze protection or control piping requirements for system operation are the sole responsibility of the Installing Contractor and/or Design Engineer. Refer to ASHRAE handbooks and local building codes for correct piping procedures and proper installations. Refer to the submittals for coil performance design information. Condensate Drain Trap (ERV3000i/e Only) Cooling coil drain pan is provided with a 1¼ MPT drain connection. A drain trap and condensate line of equal size must be field provided on the drain connection to prevent air or sewer gases from being pulled into the unit caused by the negative (suction) pressure and forcing water out of the pan into the unit. A label with recommended standard trap height is provided on the unit as per Figure 3. Condensate drain must be trapped as shown. Refer to IOM for further instructions and maintenance. Le drain de condensation doit être fabriqué et intallé tel que le croquis ci-bas. Voir le manuel d installation, opération et maintenance pour instructions. Removable plug Bouchon amovible Cleanout Roofcurb top face Orifice de nettoyage Costière face supérieure Removable plug Bouchon amovible [168 mm] 6,627 po [168 mm] 6.0 [152 mm] minimum 6,0 po [152 mm] minimum Cleanout Orifice de nettoyage Unit baserail Traverses de base Curb Bordure Figure 3: Condensate drain trap label 3.0 [76 mm] min. 3,0 po [76 mm] min. PN VCES-ERV-IOM-4A ERV

19 The trap height allows for the maximum suction pressure after the cooling coil with intake damper, dirty pre and final high efficiency filters, heat wheel, plus 1 w.c. per ASHRAE guidelines for outdoor unit with intake hood or indoor unit with up to 0.5 w.c. external static pressure loss intake duct. Slope the drain lines downward in direction of flow 1/8 inch per foot referring to local codes for proper drainage requirements. Installing a plug for cleaning of the trap is recommended. Prime the trap by filling with water before start-up. Winterize the drain line before freezing on outdoor units. Check and clear drains annually at start of cooling season. Drainage problems can occur should drains be inactive and dry out, or due to reduced water flow caused by buildup of algae. Regular maintenance will prevent these problems from occurring. Systems Integration Forced Air System When the ERV is installed in conjunction with a forced air system, the air handler and the network of ducts associated with it are used to distribute fresh air inside the building. If this type of system is used, the main fan of the air handler must operate continuously when the unit is on. Fan interlock can be connected in the unit control box to the integrated control board terminals J3-1 and J3-2 (for low voltage Class II circuit only). The controller makes relay contact between these terminals when the unit is operating, as shown in Figure J COMM. N/C N/O 1 J2 J power control board J4 JU1 JU1G Intermittent standy (IS) JU1F Extended defrost A B C D E F G F F I OC OL Y R G B Fresh air from the ERV should be introduced into the return duct of the air handler at a point no less than 6 feet [1,829 mm] upstream of the air handler. The duct connection for return air to the ERV should be made on the return air duct at least 2 feet [610 mm] upstream of the fresh air duct connection. Separate Systems Select locations for exhaust grilles and supply diffusers to provide effective ventilation and avoid short circuiting airflows through the space. Adjustable dampers should be provided at every grille and diffuser to make balancing of the system possible. Backdraft Damper A backdraft gravity damper is supplied with recirculation defrost units to be installed in the exhaust air outlet duct on indoor units. This damper is necessary to prevent air from entering the building through the exhaust duct when the unit is in recirculation defrost mode. See Appendix I for backdraft damper dimensions. Fan interlock contacts Figure 4: Fan interlock VCES-ERV-IOM-4A ERV

20 Electrical Connections! WARNING When installed, the unit must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA70, and/or the Canadian Electrical Code CSA C22.1. Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. Failure to follow this warning could result in the Installer being liable for personal injury of others. Power Supply Units are available in all voltages and phases. Please see Appendix J for electrical data. Check nameplate for correct power supply requirements. These units do not have a factory installed disconnect switch. An optional disconnect switch is available if requested and is shipped separately for field installation. If disconnect is field supplied, provide and install disconnect as per NEC/Canadian Electrical Code. Use copper conductors only. All field wiring must comply with NEC and local requirements. In Canada, electrical connections must be in accordance with CSA C22.1 Canadian Electrical Code Part One. Field Connection Location of required wire connections are shown in Appendix B. A wiring diagram is located on the control box lid inside the unit. See Appendix F for location of components and control box. For indoor units a junction box or disconnect switch must be field supplied where high voltage connections are made. For outdoor units a high voltage connection (see Figure 5) is located on the outside of the unit with knockout. A field installed disconnect switch must use a liquid-tight connector between the disconnect switch and the outside panel of the unit eliminating any water penetration into the control box. Rooftop unit (cutaway shown) ¾ locknut Line disconnect switch (cutaway shown) Figure 5: High voltage field connection ¾ locknut (as seen from inside the unit) ¾ x 1-3/8 liquid-tight connector A low voltage remote control wiring interface is provided on the unit for starting, controlling sequence and monitoring. The Installer must provide wiring; for the controls that may be supplied optionally or by others to the interface terminals. For indoor units the low voltage terminals are located on the outside of the unit enclosure. See Appendix B for location of low voltage terminals/connection. For outdoor units the low voltage remote wiring can be field run through the roofcurb, return air ductwork and return air opening to the interface terminals located inside the unit control box. The controls available for the energy recovery ventilators, their reference and type of connection are listed below. For more information on the controls, wiring and terminal connections see Appendix G. The wall control is 12 VDC; other terminals are 24 VAC or dry contact control. Note: 1. Check the Controls and/or the Control Schematic sections of the specification, optional and accessory items shipped loose with or inside the unit for a list of optional controls or wiring connections required to the unit. 2. For the unit to start both ventilation and fan speed calls are required except as noted. For ventilation call the remote wall control, occupied timer/sensor, manual switch or BMS contacts can be used. For fan speed call the remote fan control, CO 2 ventilation control, manual switch or BMS contacts can be used. Wall control connection Four-wire LVT 24 gauge minimum (12 VDC) Occupied timer/sensor connection Makes a dry contact to operate unit. Timer requires 24 VAC. Do not use timer with Xtra wall control. Note: When the wheel rotation sensor option is included, the timer dry contact must be connected to either low or high speed remote fan control terminals to operate unit. Enthalpy control 24 VAC Remote fan control Requires single pole, double throw switch for Low Common High Makes dry contact for speed setting Dirty filter sensor Makes dry contact Wheel rotation sensor used as low temperature control (wheel failure) Makes dry contact Wheel rotation sensor Makes dry contact CO 2 ventilation control Makes dry contact Unoccupied recirc contacts 24 VAC Smoke detector Makes dry contact VCES-ERV-IOM-4A ERV

21 Start-up Pre Start-up Procedure Before requesting start-up, check that the installation is complete and unit is ready. Complete the pre start-up checklist below and in Appendix M for each unit as items are checked. For torque values on set screws, belt tension, belt alignment, etc., check under Maintenance. 1. Check the electrical disconnect is in the Off position. 2. Open access doors and check the unit for shipped loose parts, obstructive packaging, objects near or in fans, dampers, enthalpy wheel, etc. Remove all red tie down bolts on fan assemblies and heat wheel if so equipped. IMPORTANT For ERV2000i/e only, remove the additional shipping brackets from the enthalpy wheel. Failure to do so could severely damage the wheel surface and void the warranty. Figure 6: ERV2000i/e shipping brackets 4. Check belt alignment and tension. 5. Check that the air filters are installed and clean. Replace if necessary. If filters are equipped with optional differential pressure switch, check that desired setpoint does not exceed factory setting of 0.8 w.c. [200 Pa]. 6. Check coils (if equipped) if fins have been damaged in transit or construction and are clean. Straighten fins with fin comb and clean coil if required. 7. Check damper and linkages for free movement. 8. Check that ductwork is connected and complete. 9. Check that condensate drain connection (if equipped) has been trapped, installed correctly and filled. 10. Check that all shipped loose or field supplied components have been correctly installed and wired. 11. Check that all power supplies and control wiring have been inspected and approved by the Local Authorities having jurisdiction. 12. Check all factory and field wiring connections for tightness. Tighten if necessary. 13. Check that all fuses are properly installed in holders. 14. Check the voltage at the disconnect switch against the nameplate and against phase-to-phase readings on three-phase. If the voltage is not within 10% of rated or 2% of phase-to-phase, have the condition corrected before continuing start-up. 15. Check that all field piping, venting and wiring installation and connections for the heating and cooling options (if equipped) have been completed and tested. 16. Check and adjust thermostat setpoints. 3. Check that the fans and heat wheel are rotating freely. Start-up Procedure To ensure proper operation of each unit, qualified personnel should perform the start-up and complete the checklist below and the start-up form in Appendix M for permanent record. A completed checklist will provide valuable information for personnel performing future maintenance. IMPORTANT A completed copy must be sent back to the factory for warranty validation and for factory assistance. All units are factory run tested. Fans and heat wheel are set up to run correct when power is connected. If any one fan is running backwards, disconnect power and switch two leads (on three-phase power) to ensure proper rotation and avoid damage. All units are dynamically balanced prior to shipping. However, there are certain operating speeds at which the natural frequency of the rotating member is attuned to the natural frequency of the unit panels, which may cause vibrations. These vibrations can tend to reinforce each other in such a way that excessive vibration can be encountered under certain conditions. It is difficult to predetermine this condition because it is affected by the mounting arrangement and the various modules used to make up the assembly and the ductwork connections. If the above check reveals no apparent discrepancies and vibration is still present, the speed of the unit should be VCES-ERV-IOM-4A ERV

22 lowered approximately 10% to determine if the natural frequency is causing the vibration. Under no condition should the unit(s) be allowed to continue to operate when excessive unit vibration is apparent. Permanent damage may result which will not be covered under warranty if the unit is allowed to continue in operation when excessive vibrations are evident. 1. Before proceeding complete the pre start-up checklist 2. For the unit to start when the disconnect switch is turned on a ventilation and fan speed call is required. a. Check for ventilation call from the remote wall control connection, occupied timer/sensor connection or BMS, whichever is used. See Appendix G for which terminal connections should be closed (contacts made) once power is connected. Circle which device is used. b. Check for either low speed or high speed (if equipped) call from the remote fan control, CO 2 ventilation control or BMS, whichever is used. See Appendix G for which terminal connections should be closed (contacts made) once power is connected. Circle which device is used. c. If a and b are not connected, start can be accomplished by using temporary external dry contacts or a jumper wire closing timer contacts 3 and 4 plus low speed contacts 13 and 14 or high speed contacts 14 and 15, Check if temporary dry contacts or a jumper wires used.! WARNING Only low or high speed contacts must be closed at any one time, never both using dry contacts/jumper wires otherwise permanent damage to the motor and wiring will occur. Remote controls, if installed and connected, operate in conjunction with the dry contacts/jumper wires. When controlling units with remote controls, use extreme caution around moving mechanical components such as fans, belts and motors as they can lead to severe personal injury. 3. Check that all access panels or doors are closed. 4. Turn the unit disconnect switch to the On position. IMPORTANT On initial power up, the unit will perform a system check and operate at high speed for five seconds. 5. Check that dampers are operating properly. 6. Wait for fans to run and then shut off unit s disconnect switch. Check that fans and enthalpy wheel are rotating in the correct direction. To reverse fan rotation, interchange two wires on load side of threephase power supply. 7. Close all access doors and turn the unit s disconnect to the On position. 8. Re-check the voltage at the disconnect switch against the nameplate and against phase-to-phase readings on three-phase with all fans operating. If the voltage is not within 10% of rated or 2% of phase-to-phase have the condition corrected before continuing start-up. 9. Check amperage draw to each motor on each phase against motor nameplate FLA. Do not allow the motor s amp draw to exceed the motor Manufacturer s nameplate data. Excessive amp draw will cause premature failure of the motor and void the motor warranty. If significantly different, check ductwork static and/or take corrective action. 10. Check the operation of the control options and accessories provided with the unit. See Frost Control, Sequence of Operation and Appendix G for functional descriptions and further details. 11. Check the setpoints on thermostats and controls, adjust and record changes as required. 12. When unit has achieved steady state take measurements and complete the readings section of the start-up form in Appendix M and send copy of the start-up form to Venmar CES to validate warranty. Maintain a copy of the report at the unit for future reference. VCES-ERV-IOM-4A ERV

23 Frost Control Recirculation Defrost Recirculation defrost is a temperature initiated timebased cycle which will de-energize the exhaust fan and the wheel drive motor, close the outdoor air damper and circulate return air through both sides of the wheel. If recirculation is in operation, it will run approximately 15% of the time, only when the outdoor air temperature falls below 5 F [ 15 C]. Exhaust Only Defrost Exhaust only defrost is a temperature initiated time-based cycle which will de-energize the supply fan, close the outdoor air damper and exhaust return air through the exhaust side of the wheel as it continues to rotate. If exhaust only is in operation, it will run approximately 15% of the time, only when the outdoor air temperature falls below 5 F [ 15 C]. Pre-heat Frost Prevention Pre-heat frost prevention is an outdoor air temperature controlled function that allows for continuous ventilation by monitoring the outdoor air temperature and ensuring a minimum entering air temperature (into the enthalpy wheel) of 5 F [ 15 C]. There are fixed kw capacity options available based upon the unit model. For pre-heat capacity requirements, please use applicable ASHRAE formulas. Pre-heat frost prevention can have two-stage, four-stage or SCR control. VSD (Variable Speed Drive) Frost Prevention This variable speed frost prevention option is an exhaust air temperature controlled function that allows for continuous ventilation by reducing the enthalpy wheel rotational speed. The rotational speed and therefore effectiveness of the enthalpy wheel, is modulated to maintain an exhaust air temperature of 33 F [1 C]. This modulation maintains the wheel operating temperature at conditions that prevent frost formation. Special consideration must be given to applications where supply air is being heated, as the heating capacity maximum condition will be during the frost prevention cycle. IMPORTANT VSD frost control may cause supply air temperatures to be below freezing. Adequate freeze protection, such as glycol or low limit temperature protection for downstream coils or reheat to protect building systems, must be field provided. Non-defrost No frost control is required in areas where the winter outdoor air condition stays above 5 F [ 15 C] and the return air humidity level is below 30%. Sequence of Operation IMPORTANT On initial power up, the unit will perform a system check and operate at high speed for five seconds. Unit Checkpoints Power connected, no ventilation call Both fans are off, supply damper (if equipped) closes off outdoor air. Power connected, low speed call (optional) Both fans on low speed, supply damper (optional) opens outdoor air, recirculation defrost damper (optional) remains closed. Exhaust damper (optional) opens. If unit is single-speed, it will come on that speed on a call for low or high. Power connected, high speed call Both fans on high speed, supply damper (optional) opens outdoor air. Recirculation defrost damper (optional) remains closed. Exhaust damper (optional) opens. If unit is single-speed, it will come on the speed on a call for low or high. Power connected, occupied timer/sensor connection open (factory installed jumper removed/unoccupied mode) Both fans are off, recirculation defrost damper (optional) remains closed. Supply and exhaust dampers (optional) are closed. Power connected, enthalpy control contacts closed, unit ventilating Wheel stops rotating, fans stay on set speed, recirculation defrost damper (optional) remains closed. Supply and exhaust dampers remain open. Power connected, enthalpy control contacts closed, unit not in ventilation mode Wheel does not rotate, fans come on low speed (optional); if unit is singlespeed, it will come on that speed on a call for low or high. Recirculation defrost damper (optional) remains closed, supply and exhaust dampers open. Power connected, recirculation defrost (optional factory installed) Recirc contacts are closed, exhaust fan is de-energized, supply fan runs and recirculation damper opens. VCES-ERV-IOM-4A ERV

24 Airflow Balancing For proper performance the unit must operate at the specified supply and exhaust flow rates. Unit fan speed(s) are theoretically set at the factory based on the ductwork static pressures and flow rates specified with the order and in the performance data. If conditions change or verification is required, airflow measurements should be taken using AMCA suggested methods. This would normally be a velocity traverse measurement or flow measuring station (FMS) installed in the ducts as shown in Appendix D. It is important to locate the FMS in the warm side ductwork to minimize the effect of differences in air density, especially when balancing during extremely cold outside conditions. Air density variations can affect the FMS by more than 15%. The FMS should be located downstream from straight sections of duct and not immediately after fans or obstructions that will cause turbulent flow. Flow control dampers should be installed downstream from the FMS so flow through the FMS is not disturbed. Dampers can then be adjusted to equalize flow rated in the ducts. Where space is limited in the outdoor air and exhaust air ductwork, pressure drop readings can be taken across the enthalpy wheel and read or calculated from the Enthalpy Wheel Pressure Drop vs. Flow Formula and Tables located in Appendix K for the wheel diameter and thickness or efficiency rating. Heat recovery performance is tested in accordance to AHRI Standard 1060 and is accurate to within +/ 5% if there is no dirt buildup in the heat recovery wheel. Setting Flow Rates Units supplied with belt driven double width double inlet fans have an adjustable motor sheave factory set at the midpoint of travel at rpm for the flow rate and external static specified. With optional VFD driven motors this factory setting is at 60 Hz. For outdoor and exhaust, airflow rate should be balanced with motors operating at high speed and at 60 Hz by adjusting the motor sheave pitch diameter. The VFD can be used for fine tuning depending on sequence or as required. Units supplied with direct driven single width single inlet fans operate at the motor rpm. Flow rate must be balanced on jobsite by adjusting field supplied and installed balancing dampers as shown in Appendix D and measuring airflow as described in Airflow Balancing. Maintenance! WARNING Disconnect the main power switch to the unit before performing service and maintenance procedures. See Appendix F for component locations, Appendix H for troubleshooting information and Appendix L for a recommended list of routine maintenance items and time intervals. A more detailed description of maintenance items follows. The standard medium efficiency filters and optional high efficiency filters (ERV3000e only) are disposable and should be replaced every three months. More frequent replacement may be required under extremely dirty operating conditions. Air Filters To remove the exhaust filters in the ERV1000i and ERV2000i/e, remove the screw holding the filter access door and slide the exhaust filter access door down to the bottom of the unit. The filters are set in frames and can be removed by pulling on the filter tabs and sliding them forward and out of the unit. First, the right filter must be removed, then the left filter must slide over to where the right filter was, then pull it forward and out of the unit (see Figure 7). Figure 7: Exhaust filter access ERV1000i and ERV2000i/e VCES-ERV-IOM-4A ERV

25 ! WARNING Disconnect the main power switch to the unit before performing service and maintenance procedures. To replace the ERV1500i/e and ERV3000i/e filters, remove the enthalpy wheel access door. Grasp the filter frame at the left and right edges and pull straight out (see Figure 8 & Figure 9). The filter frame will slide completely out of the unit. Pull the filters up and out the top of the frame. Place the new filters into the frame and slide the frame back into the unit. Replace the enthalpy wheel access door. For filter specifications, see Appendix I. Figure 9: Filter access ERV1500i/e and ERV3000i/e Figure 8: Filter access ERV1500i/e and ERV3000i/e Remove the filters from the unit. Wipe the interior foil faced insulation or optional galvanized steel liner surfaces and enthalpy wheel cassette panels with a soft cloth and mild cleaning solution. Interior of Unit VCES-ERV-IOM-4A ERV

26 Fans! WARNING Disconnect the main power switch to the unit before performing service and maintenance procedures. ERV units may be fitted with direct driven fans and motors (ERV500i/e and ERV1000i) or belt driven fans. Belt driven fans are provided with either spider bracket bearings which come pre-lubricated from the Manufacturer and require no re-lubrication, or with pillow block bearings which are pre-lubricated. Pillow block bearings should be lubricated at six to twelve month intervals. The recommended lubricant is Shell Alvania #2 or S3. A small amount of grease should be added slowly while the shaft is rotated. Note: Over greasing may cause damage to the bearing. Avoid rupturing the bearing seal. Fan wheels and fan housings should be checked for dirt buildup. If they are dirty, it will be necessary to remove the blower assembly to clean the dust out through the fan discharge. Direct Driven Fan and Motor Removal (ERV500 shown) Exhaust After disconnecting the power from the unit, disconnect all the plug-in connectors on the left side of the control box. Figure 11: Remove control box cover To remove the exhaust blower, unscrew the two wing nuts used to fasten the blower assembly to the middle shelf in the unit. Rotate the blower assembly and slide it out of the unit. Figure 12: Remove exhaust blower Figure 10: Disconnect plug-in connectors Supply After disconnecting the power from the unit, disconnect the three-wire connector between the supply motor and control box. Remove the four Phillips head screws holding the control box cover. Using a ¼ nut driver, remove the four hex head screws holding the control box to the unit. Remove the control box to gain access to the exhaust blower assembly. Figure 13: Disconnect three-wire connector VCES-ERV-IOM-4A ERV

27 ! WARNING Disconnect the main power switch to the unit before performing service and maintenance procedures. result in noise from excessive vibration, premature bearing failure and short belt life. Tight belts may overload a motor that would otherwise be adequate. To remove the supply blower, unscrew the four wing nuts used to fasten the blower assembly to the middle shelf of the unit. Slide the blower assembly out of the unit. Figure 14: Remove supply blower Belt Driven Fan and Motor Removal (ERV2000 shown) After disconnecting the four-wire service connector between the motor and the control box (#1, Figure 15), loosen the two front bolts (#2, Figure 15). Remove the two back bolts (#3, Figure 15). Slide the fan assembly away from the discharge opening and lift out of the unit. Figure 16: Belt tension adjustment To adjust the belt tension, loosen the two pivot bolts (#1, Figure 17). Loosen the two adjustment bolts (#2, Figure 17). Rotate the motor and base plate to achieve the maximum belt deflection as described above. Tighten the drive belt side adjustment bolt. Adjust the motor plate so that the sheave and pulley faces are parallel and the belt is aligned. Tighten the remaining adjustment bolt and the two pivot bolts. Verify that the sheave and pulley faces are still parallel. The fan rpm can be adjusted to achieve the design airflow by setting the adjustable sheave on the motor shaft. The pulley set screw torque setting is 110 in-lbs to 130 in-lbs. Figure 15: Supply fan (ERV2000 shown) Belt Tension Adjustment Excessive belt tension is the number one cause of fan bearing failure. Proper belt tension and pulley alignment are essential for trouble free operation. A simple rule of thumb for checking belt tension is illustrated in Figure 16. When the belt is grasped as shown in, a total deflection of approximately 1 [25 mm] should be attained. Insufficient deflection indicates that the belt is too tight, which may Figure 17: Motor (ERV2000 shown) VCES-ERV-IOM-4A ERV

28 Enthalpy Wheel! WARNING Disconnect the main power switch to the unit before performing service and maintenance procedures. General No cleaning of the enthalpy wheel is required; it is selfcleaning due to the opposing airflows. If the enthalpy wheel needs to be cleaned, use low pressure air or vacuum. Wash the cassette panels with a soft cloth and mild cleaning solution. Visually inspect the cassette brush seals (see Figure 18), perimeter seal and drive belt for proper operation. Face Seal Replacement and Adjustment Complete the following instructions to replace the brush seal on both sides of the cassette. On the belt side of the cassette, remove the two Phillips screws holding the air filter guide to the cassette assembly. Remove the additional Phillips screw holding the brush seal to the cassette assembly. On the motor side of the cassette, remove the three Phillips screws holding the brush seal to the cassette assembly. Rotor Brush.seal Figure 18: Cassette brush seals ERV500 Enthalpy Wheel Cassette Removal After disconnecting the power from the unit, disconnect the two three-wire connectors located on the metal frame of the cassette assembly. Both connectors are positioned at the front of the cassette assembly, one connector located at the top right position and the other at the bottom left position on the cassette frame. Disconnect the threewire connector from the control box being used to supply power to the cassette motor. IMPORTANT Use extreme care when removing or installing the cassette assembly. Damage to the cassette media may result in poor unit efficiency and may void the warranty. Figure 20: Remove screws holding brush seal to cassette assembly Install the new brush seals so that the bristles come in contact with the cassette. Reverse the procedures above to re-install the brush seals and the air filter guide. Enthalpy Wheel Drive Belt Replacement and Tensioning Adjustment To replace the cassette drive belt, the brush seal located on the drive belt side of the cassette must be removed. Complete the steps in the previous section for the removal of the brush seal prior to completing the following procedures. The cassette beam assembly must be removed to gain access to the cassette drive belt. To remove the cassette beam assembly, remove the three Phillips screws used to fasten the cassette beam cover. Figure 19: Remove cassette assembly Figure 21: Remove cassette beam assembly VCES-ERV-IOM-4A ERV

29 ! WARNING Disconnect the main power switch to the unit before performing service and maintenance procedures. Using a 1/8 Allen key, loosen the two set screws used to tighten the cassette bearing to the cassette shaft. The set screws are located in-line with the cassette shaft, between the cassette and the cassette beam. After loosening one set screw, it will be necessary to rotate the wheel a half turn to access the second set screw. Figure 24: Remove belt from cassette Install the new belt onto the cassette and adjustable sheave (pulley). Re-install the outer half of the adjustable sheave by rotating it clockwise onto the threaded shaft. This process will be used to tighten the belt around the perimeter of the cassette. Do not tighten the belt onto the cassette until the beam assembly has been reinstalled. Figure 22: Loosen set screws Using a 7/16 nut driver, remove the four ¼ bolts holding the cassette beam to the cassette frame. The cassette beam can now be removed and placed aside to re-install later. Reverse the above procedures to re-assemble the cassette assembly. It will also be necessary to complete the steps in the previous sections that were used to install the cassette brush seal and the cassette. ERV1000 to ERV3000 Enthalpy Wheel Cassette Removal After disconnecting the power from the unit, open the service door for the cassette access. Disconnect the service connector between the motor and the control box. Remove the exhaust filters and slide the cassette out of the unit. Take care not to damage the rotor face or any of the cassette seals. Proper support must be provided so the cassette is not dropped. Perimeter Seal Replacement CAUTION When handling the enthalpy wheel, ensure not to damage the face of the wheel. Figure 23: Remove cassette beam bolts Remove the outer half of the adjustable sheave (pulley). Using a 5/32 Allen key, loosen the set screw located on the outer half of the adjustable sheave. Remove the outer half of the adjustable sheave by turning it counterclockwise. This sheave piece is threaded and therefore it will take a few rotations to completely remove it. Once removed, slide the belt off the cassette. To replace the perimeter seal, the enthalpy wheel must be removed from the frame. Disconnect the service connector to the drive motor of the enthalpy wheel cassette. Remove the cassette from the unit and stand the assembly on the floor or roof. Remove the dust cap (#1, Figure 25) from the bearing on the drive motor side of the cassette. Remove the bolt (#2, Figure 25) from the end of the wheel shaft with a socket or wrench on the drive motor side. Repeat this procedure for the other side of the cassette assembly. Remove the four bolts (#3, Figure 25) with a socket or wrench. Remove the beam and bearing assembly from the end of the wheel shaft. Loosen the four Nyloc nuts (#1, Figure 26) holding the drive motor using a socket VCES-ERV-IOM-4A ERV

30 ! WARNING Disconnect the main power switch to the unit before performing service and maintenance procedures. or wrench. Rotate the drive motor in the slots to loosen the drive belt and remove the belt. Lift the enthalpy wheel out of the frame with assistance and set aside. Remove the perimeter seal halves (#4, Figure 25) from the cassette frame assembly. Install the two new perimeter seal halves by pressing them into place, cutting to the correct length as necessary. The perimeter seals are non-adjustable. Complete the installation by reversing the above procedure. roof. Remove the screws holding the face seals (#5, Figure 25). Replace the two seals (supply and exhaust sides), cutting to length as required. Adjust the seals in the slots so that the brush just touches the face of the wheel. Complete the installation by reversing the above procedure. Enthalpy Wheel Drive Belt Replacement and Tensioning Adjustment The enthalpy wheel drive belt can be tightened by only sliding the cassette assembly part way out of the unit. Disconnect the service connector to the drive motor of the enthalpy wheel cassette. Slide the cassette assembly out of the unit enough to access the drive motor. Loosen the four Nyloc nuts (#1, Figure 26) holding the drive motor using a socket or wrench. Rotate the drive motor to loosen the belt and replace the belt if necessary. Rotate the drive motor in the slots to tighten the drive belt. Secure the motor in it s new location by tightening the four Nyloc nuts. (#1, Figure 26). Complete the installation by reversing the above procedure. Figure 25: Cassette and drive Face Seal Replacement and Adjustment CAUTION When handling the enthalpy wheel, ensure not to damage the face of the wheel. To replace the face seals, the cassette assembly must be removed from the unit. Disconnect the service connector to the drive motor of the enthalpy wheel cassette. Remove the cassette from the unit and stand up on the floor or Figure 26: Cassette and drive Testing and Replacement of the Damper Actuator After disconnecting the power from the unit, determine if the actuator is defective. Disconnect the 24V power source. Connect the actuator directly to a 24V power source with an appropriate cable. If the damper operates correctly, the problem is either in the wiring connections or main circuit board. If the actuator does not work, it must be replaced. Loosen the nuts on the jack shaft clamp, remove the actuator. Tighten the clamp on the damper jack shaft. Test for proper operation. VCES-ERV-IOM-4A ERV