INSTALLATION INSTRUCTIONS

Transcription

1 INSTALLATION INSTRUCTIONS MAXA-MI$ER UNITARY ENERGY RECOVERY VENTILATOR MODEL VR028A15M/H & VR028A25H (STATIONARY) A-0709 / R28A-18YDW Energy recovery COMPONENT certified to the AHRI Air-to-Air Energy Recovery Ventilation Equipment Certification Program in accordance with AHRI Standard Actual performance in packaged equipment may vary. ETL Certified per UL 1995 and CSA 22.2 I - Ship ping And Pack ing List Package 1 of 2 contains: 1 - Energy Recovery Ventilator Assembly 1 - Outdoor Fresh Air Hood w/ Filter 1 - Outdoor Exhaust Hood w/ Barometric Dampers Package 2 of 2 contains: 1 - Balancing Damper Assembly 1 - Platform Support Rail 2 - Door Panels 1 - Bag Assembly 1 - Roll of ¾" x 1 ¼" gasket 1-272" of 1 8" x ½" gasket 1 - Field Wiring Harness 1 - Adapter Wiring Harness 10 - #14 Screws 30 - #10 x ½" Gold Screws 1 - Installation Instructions II - Ship ping Dam age Check unit for shipping damage. Receiving party should contact last carrier immediately if shipping damage is found. III - Gen eral These instructions are intended as a general guide and do not supersede local codes in any way. Authorities having jurisdiction should be consulted before installation. IV - Re quire ments When installed, the unit must be electrically wired and grounded in accordance with local codes or, in absence of local codes, with the current National Electric Code, ANSI/NFPA No. 70. V - Application Unitary Energy Recovery Ventilator (UERV) are used with 3 to 6 ton rooftop units equipped with a balancing damper assembly. These wheels conserve energy by mixing warmer air with cooler air in the following manner: Recovery Wheel Mode The Recovery Wheel mode is accomplished by two blowers providing continuous exhaust of stale indoor air and replacement by equal amount of outdoor air. Energy recovery is achieved by slowly rotating the energy recovery wheel within the cassette frame work. In winter, the UERV adsorbs heat and moisture from the exhaust air stream during one half of a complete rotation and gives them back to the cold,drier intake air supply during the other half rotation. In summer, the process is automatically reversed. Heat and moisture are absorbed from incoming fresh air supply and transferred to the exhaust air stream. This process allows outdoor air ventilation rates to be increased by factors of three or more without additional energy penalty or increase in size of heating or air conditioning systems. PAGE 1 VI - Rig ging Unit For Lift ing 1. Maximum weight of unit is Lbs. (Crated) 2. Remove crating. Then remove access panel to retrieve bag assembly. Replace access panel. 3. All panels must be in place for rigging. 4. Lifting lugs are supplied with the unit. Loosen machine bolts and rotate lifting lug. WARNING Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch(es). Unit may have multiple power supplies. CAUTION Danger of sharp metallic edges. Can cause injury. Take care when servicing unit to avoid accidental contact with sharp edges. VII - Installation 1. Disconnect all power to rooftop unit. 2. Remove the rooftop unit horizontal and return air access panels. Also remove any hoods and/or power exhaust equipment. Discard hoods, power exhaust equipment horizontal supply and return air access panels. See Figure Remove return duct cover in the floor of rooftop unit.

2 INSTALLATION INSTRUCTIONS MAXA-MI$ER UNITARY ENERGY RECOVERY VENTILATOR MODEL VR028A15M/H & VR028A25H (STATIONARY) A-0709 / R28A-18YDW 4. Remove 9 screws holding painted outside center post between horizontal return air openings. 5. Remove clip, two screws on the top and two 3 8" head screws on the bottom to remove inside galvanized center post. See Figure 2 and Install balancing damper assembly. Reinstall painted outside center post. See Figure 4 and Adjust balancing damper to minimum air flow requirements by loosening the set screw and moving adjustable rod to desired setting. See Figure Locate the provided field wiring harness and plug into the economizer plug of the rooftop unit. If rooftop unit has 12 pin plug, the provided adapter will be needed. Route field harness through balancing damper so connection can be made to UERV after installation. See Figure Locate the two provided door panels. Secure the door panels to the horizontal return openings using the provide #10 x ½" screws. See Figure Locate the provided platform support rail. Align the platform support rail with the center post of the rooftop units return opening. Attach the platform support rail to the upper set of holes in the door panel using the provided #14 screws. See Figure Using lifting lugs, raise UERV unit approximately three (3) feet. Remove nut and bolt assembly to slide telescoping part of leg out of guide. Position standoff legs so that flat foot is on bottom of stand and reinstall nut and bolt assembly. Do not fasten tightly, adjustment will need to be made when unit is put into position. 12. Apply the provide ¾" x 1 ¼" gasket down the center of the UERV back panel and between platform support rail and door panels. 13. Lift and move UERV unit into position in front of horizontal exhaust air opening. Note: A treated 2" x 6" x 60" piece of wood or equivalent should be used under feet of standoff legs to prevent roof penetration. 14. Remove screws from top panel of rooftop unit. Ensure top will move up at least 2". 15. Lower UERV into bottom support plate catching the front edge of the UERV bottom into the ½" flange. With the UERV in place, adjust the standoff legs to level and support UERV against rooftop unit. Tighten securely. Rotate lifting lug to original position and tighten machine bolts 16. Place UERV top flange under the rooftop unit top panel secure the rooftop unit top panel with existing screws. See Figure Secure the side flanges of the UERV to the holes in the door panels installed earlier with the provide #10 x ½" screws. 18. Locate the plug extended from back of UERV through opening in door panel. Connect this plug to the field wiring harness installed earlier. REMOVE FILTER ACCESS Figure 1 REMOVE Figure 2 REMOVE Figure 3 PAGE 2

3 INSTALLATION INSTRUCTIONS MAXA-MI$ER UNITARY ENERGY RECOVERY VENTILATOR MODEL VR028A15M/H & VR028A25H (STATIONARY) A-0709 / R28A-18YDW 19. Seal, if required, along face (top and sides) of UERV unit where it meets rooftop unit to insure no air leakage. Final assembly should resemble Figure All electrical connections must conform to any local codes and current National Electric Codes (NEC) and Canadian Electric Codes (CEC). Refer closely to unit wiring diagram in unit and/or in these instructions for proper wiring connections. Refer to the unit nameplate for minimum circuit ampacity and maximum overcurrent protection size. Electrical data is listed on unit rating plate and motor nameplates. 21. Connect line voltage power supply to UERV unit from disconnect switch. Connect line voltage to fuse block in control box through knockout on the front of UERV. See Figure Ground unit with a suitable ground connection either through unit supply wiring or an earth ground. Note: Unit voltage entries must be sealed weather tight after wiring is complete. 23. Replace access panel onto the UERV unit and secure. 24. Restore power to unit. 25. Start system up to verify operation. 26 Balancing is done by removing the plastic plugs in door panels (4 total). 27. With a manometer measure pressure drop [ inches of water column] across the top half of UERV (top holes in door panel). Unit CFM is determined by referring to Table #1. If CFM values are not per design, adjust internal dampers inside the rooftop unit. This is accomplished by removing door panel at the return air opening, loosing screw in center of damper, then slide damper rod up or down in the return airstream and re-tighten screw. Replace door panel and repeat measurement method. 28. Place plastic plugs back into door panels. 29. Cleanup once UERV is operating properly. Caulk any open joints, holes or seams to make the unit completely air and water tight. 30. Fill out installation checklist and start-up sheet in back of this instruction. 31. Leave this instruction manual with owner or in an envelope to be kept near the unit. VIII - Operation How It Works The unit contains an Energy Recovery Wheel (ERW) that is a new concept in rotary air-to-air heat exchanger. Designed as a packaged unit for ease of installation and maintenance, only matching up to rooftop unit with an internal balancing damper and connection of electrical power is required to make the system operational. The concept consists of a unique rotary energy recovery wheel that rotates in and out of fresh air streams within a heavy duty, permanently installed blower cabinet that provides ready access to all internal components. The media is polymeric material that is coated and permanently bonded with a dry desiccant for total enthalpy recovery. The wheel is belt driven by PSC motor and drive belt. PAGE 3 BALANCING DAMPER Figure 4 REINSTALL CENTER POST Figure 5 ADJUSTMENT ROD Figure 6

4 INSTALLATION INSTRUCTIONS MAXA-MI$ER UNITARY ENERGY RECOVERY VENTILATOR MODEL VR028A15M/H & VR028A25H (STATIONARY) A-0709 / R28A-18YDW When slowly rotating through counter flowing exhaust and fresh air streams the UERV adsorbs sensible heat and latent heat from the warmer air stream and transfer this total energy to the cooler air stream during the second half of its rotating cycle. Rotating at 60 revolutions per minute, the wheel provides constant flow of energy from warmer to cooler air stream. The large energy transfer surface and laminar flow through the wheel causes this constant flow of recovered energy to represent up to 85% of the difference in total energy contained within the two air streams. Sensible and latent heat are the two components of total heat. Sensible heat is energy contained in dry air and latent heat is the energy contained within the moisture of the air. The latent heat load from the outdoor fresh air on an air conditioning system can often be two to three times that of the sensible heat load and in the winter it is a significant part of a humidification heat load. During both the summer and winter, the UERV transfers moisture entirely in the vapor phase. This eliminates wet surfaces that retain dust and promote fungal growth as well as the need for a condensate pan and drain to carry water. Because it is constantly rotating when in the air stream, the UERV is always being cleared by air, first in one direction then the other. Because it is always dry, dust or other particles impinging on the surface during one half cycle, are readily removed during the next half cycle. Additional Information for Options are provided in Options Manual. Re cov ery Mode On a thermostat call for blower operation in heating, cooling or continuous blower, the ERW will rotate between fresh air and exhaust air streams. Both the fresh air and exhaust air blowers will also be operating to overcome the air resistance of the UERV. IX - Sys tem Check 1. Disconnect main power. 2. Turn thermostat to "Cont" for blower operation. 3. Restore power to unit. Observe UERV wheel rotation and both fresh air and exhaust air blowers will operating. Note: If Low ambient kit is used the jumper between TB37-5 & TB37-6 should be removed. Also if system check out is being conducted at low ambient temperatures, technician should be aware that this kit can cause system not to operate. 4. Verify that the UERV (3) three phase blower motors are phased sequentially ensuring correct rotation and operation. a) Disconnect power. b) Reverse any two field power leads to the UERV. c) Reapply power. FIELD HARNESS Figure 7 DOOR PANELS Figure 8 Figure 9 PLATFORM SUPPORT RAIL PAGE 4

5 INSTALLATION INSTRUCTIONS MAXA-MI$ER UNITARY ENERGY RECOVERY VENTILATOR MODEL VR028A15M/H & VR028A25H (STATIONARY) A-0709 / R28A-18YDW A - Return Damper Set tings Manually adjust position of dampers. This is accomplished by loosing and tightening set screw on positioning rod. B - Blower Speed Ad just ment Blower speed selection is accomplished by changing the sheave setting on both fresh air and exhaust air blowers. Both blowers are factory set at "closed" for maximum airflow. To determine air flow setting, external static pressure readings will need to be read across the UERV. See Figure 11 and 12 for location to take pressure readings. C - Air Bal anc ing Ad just ment 1. Remove plastic plugs in door panels(4 total). 2. With a manometer measure pressure drop [inches of water column] across top half of UERV (top holes in door panel). Unit CFM is determined then by referring to Table #1. If CFM values are not per design, adjust intake motor sheave and repeat measure method. 3. Repeat the same process for the bottom half of UERV. If CFM values are not per design, adjust internal dampers inside the rooftop unit. This is accomplished by removing door panel at the return air opening, loosing screw in center of damper, then slide damper rod up or down in the return airstream and re-tighten screw. Replace door panel and repeat measurement method. 4. Place plastic plugs back in to door panels. X - Main te nance Motor Maintenance All motors use prelubricated sealed bearings; no further lubrication is necessary. Mechanical Inspection Make visual inspection of dampers, linkage assemblies and UERV rotating bearings during routine maintenance. Filters should be checked periodically and cleaned when necessary. Filter is located in fresh air hoods. DO NOT replace permanent filters with throwaway type filters. Belt Alignment Proper alignment is essential to maintain long V-Belt life. Belt alignment should be checked every time belt maintenance is performed, each time the belt is replaced, and whenever sheaves are removed or installed. Belt Installation Always move the drive unit forward so the belt can be easily slipped into the groove without forcing them. Never force the belt into a sheave with a screw driver or wedge. You will damage the fabric and break the cords. It is recommended that the pulley center distances be offset by ¾" for proper length. This will allow the motor assembly to slide forward to remove belt and backward for belt tension. Belt Tension Measure the span length (center distance between pulleys when belt is snug). Mark center of span, then apply a force (6 to 9 Lbs on new belts) perpendicular to the span large enough to deflect the belt 1 64" for every inch in span length. UERV TOP FLANGE UNDER RTU TOP Figure 10 DELTA PRESSURE (FRESH AIR) Figure 11 DELTA PRESSURE (EXHAUST AIR) Figure 12 PAGE 5

6 INSTALLATION INSTRUCTIONS MAXA-MI$ER UNITARY ENERGY RECOVERY VENTILATOR MODEL VR028A15M/H & VR028A25H (STATIONARY) A-0709 / R28A-18YDW Energy Recovery Wheel Maintenance Eight pie-shaped ERW segments, are seated on stops between the segment retainer which pivots on the wheel rim and secured to the hub and rim of wheel. Annual inspection of the self cleaning wheel is recommended. With power disconnected, remove UERV access panels (rear) and unplug [J150 and P150] (Refer to wiring diagrams in this instruction manual). Remove segment and wash with water and/or mild detergent. To install wheel segments follow steps A through E. See Figure 14. Reverse procedure for segment removal. A. Unlock two segment retainers (one on each side of the selected segment opening. B. With the embedded stiffener facing the motor side, insert the nose of the segment between the hub plates. C. Holding segment by the two outer corners, press the segment towards the center of the wheel and inwards against the spoke flanges. If hand pressure does not fully seat the segment, insert the flat tip of a screw driver between the wheel rim and outer corners of the segment and apply downward force while guiding the segment into place. D. Close and latch each segment retainer under segment retaining catch. E. Slowly ro tate the wheel 180 o. In stall the sec ond seg ment op po site the first for coun ter bal ance. Ro tate the two in stalled seg ment 90 o to bal ance the wheel while the third seg ment is in stalled. Ro tate the wheel 180 o again to in stall the fourth seg ment. Re peat this se quence with the re main ing four segments. FUSE BLOCK Figure 13 SEGMENT RETAINER CATCH SEGMENT RETAINER WHEEL RIM E A D C D B SEGMENT SPOKE HUB FIGURE 14 PAGE 6

7 ENERGY RECOVERY VENTILATOR SCFM vs. PRESSURE DROP R28 Series 1100 RPM 1000 RPM 900 RPM 800 RPM PAGE 7 PRESSURE DROP (in. of W.C.) SCFM Equation of line: SCFM=(PD )/ TABLE #1

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9 UERV UNIT SCHE MATIC DI A GRAM A131 B26 B27 B28 B30 C23 DL43 F29 J33 J34 J40 J48 J50 J51 J56 J148 J150 J151 J152 J153 J160 K94 K163 K164 P33 P34 P40 P48 P50 P51 P56 P148 P150 P151 P152 P153 P160 S23 S26 S51 S125 T27 T28 BK BL GR GY OR PK RD WH YL COMPONENT CODE Fixed Re lay Board Mo tor, Ex haust Air Mo tor, Fresh Air Mo tor, Des ic cant Wheel Mo tor, Damper (Op tional) Ca paci tor, Wheel Mo tor De lay, Cy cle Timer (Op tional) Fuse Jack, Cy cle Con trol (Op tional) Jack, Cy cle Con trol Har ness (Op tional) Jack, Cy cle (Op tional) Jack, Con trol Box (Fresh Air) Jack, Con trol Box (Wheel) Jack, Con trol Box (Ex haust Air) Jack, Con trol Box (Damper) Jack, Fresh Air Mo tor Har ness Jack, Wheel Mo tor Har ness Jack, Ex haust Air Mo tor Har ness Jack, Trans former (High Volt age) Jack, Field Har ness Jack, Damper Mo tor Har ness Re lay, On/Off (Op tional) Con tac tor, Ex haust Air Mo tor Con tac tor, Fresh Air Mo tor Plug, Cy cle Con trol (Op tional) Plug, Cy cle Con trol Har ness (Op tional) Plug, Wheel Cy cle (Op tional) Plug, Fresh Air Mo tor Har ness Plug, Wheel Mo tor Har ness Plug, Ex haust Air Mo tor Har ness Plug, Damper Mo tor Har ness Plug, Fresh Air Mo tor Plug, Wheel Mo tor Plug, Ex haust Air Mo tor Plug, Trans former (High Volt age) Plug, Field Har ness Plug, Damper Mo tor Ther mo stat - Low Am bi ent (Op tional) Switch, Low Am bi ent (Op tional) Switch, Door Switch, Am bi ent Over ride (Op tional) Trans former, Con trol Trans former, Step- down (Op tional) WIRE COLOR Black Blue Green Gray Or ange Pink Red White Yellow Notes: 1. Remove jumper to install field optional low ambient switch. 2. Step-down transformer assembly for 460 volt units. 3. Selective voltage terminal for proper unit voltage 4. Optional low ambient switch. 5. Optional motorized intake damper. 6. Optional stop, start and jog control. 7. Matching adapter harness (provided) to connect with rooftop unit. For energy management systems connect +24v to green and common 24v to black. R28-18YDW PAGE 9

10 UERV UNIT WIR ING DI A GRAM Notes: 1. Remove jumper to install field optional low ambient switch. 2. Step-down transformer assembly for 460 volt units. 3. Selective voltage terminal for proper unit voltage 4. Optional low ambient switch. 5. Optional motorized intake damper. 6. Optional stop, start and jog control. 7. Matching adapter harness (provided) to connect with rooftop unit. For energy management systems connect +24v to green and common 24v to black. Des ic cant Wheel for Roof top Unit /460V/575V (3 PH) Unit#: 01- R28-01XX-23/-33/-43 PAGE 10

11 PAGE 11 EQUIPMENT LAYOUT

12 START UP INFORMATION SHEET VOLTAGE - UERV UNIT In com ing Volt age L1-L2 L1-L3 L2-L3 Run ning Volt age L1-L2 L 1-L3 L2-L3 Sec ond ary Volt age * With ther mo stat call ing. C (black) to G (green) Volts* C (black) to W (white) Volts* AM PER AGE - UERV MO TORS In take Mo tor: Nom i nal HP Rated Amps Run ning Amps Ex haust Mo tor: Nom i nal HP Rated Amps Run ning Amps Wheel Mo tor: Nom i nal HP Rated Amps Run ning Amps AIR FLOW In take De sign CFM Pres sure Drop Cal cu lated CFM Ex haust De sign CFM Pres sure Drop Cal cu lated CFM Amb. db Temp Re turn Air db Temp* Tem pered Air db Temp* Amb. wb Temp Re turn Air wb Temp* Tem pered Air wbtemp* * Mea sure af ter 15 min utes of run time INSTALLATION CHECK LIST UERV Model # Se rial # Owner Owner Phone # Owner Ad dress In stall ing Con trac tor Start Up Me chanic Inspect the unit for transit damage and report any damage on the carrier s freight bill. Check model number to insure it matches the job requirements. Install field accessories and unit adapter panels as required. Follow accessory and unit installation manuals. Verify field wiring, including the wiring to any accessories. Check all multi-tap transformers, to insure they are set to the proper incoming voltage. Verify correct belt tension, as well as the belt/pulley alignment. Tighten if needed. Prior to energizing the unit, inspect all the electrical connections. Power the unit. Bump the motor contactor to check rotation. Three phase motors are synchronized at the factory. If blower motor fans are running backwards, de-energize power to the unit, then swap two of the three incoming electrical lines to obtain proper phasing. Re-check. Perform all start up procedures outlined in the installation manual shipped with the unit. Fill in the Start Up Information as outlined on the opposite side of this sheet. Provide owner with information packet. Explain the thermostat and unit operation. Supercedes: A-1108 Sub ject to change with out no tice. Printed in U.S.A. Copy right by Uni tary Prod ucts Group All rights re served A-0709 R28A-18YDW Unitary 5005 Norman Products York OK Group Drive 73069