ClimateMaster OB Series, OD SERIES, OC SERIES, OE SERIES, OF SERIES, OG SERIES Installation Instructions Manual
Specifications and Main Features
Frequently Asked Questions
User Manual
INSTALLATION INSTRUCTIONS
97B0042N06
Rev.: 04 April, 2014
ENERGY RECOVERY VENTILATORSERIES OB, OC, OD, OE, OF & OG
Installation Instructions For Energy Recovery Ventilator (Fixed)
For Stand Alone Rooftop Application
Energy recovery COMPONENT certifi ed to the ARI Air-to-
Air Energy Recovery Ventilation Equipment Certifi cation
Program in accordance with ARI Standard 1060-2000.
Actual performance in packaged equipment may vary.
ETL Certifi ed per UL 1995 and CSA 22.2
Inspection
Upon receipt of shipment at the job site, carefully check the
shipment against the bill of lading. Make sure all units have
been received. Inspect the carton or crating housing of each
Rooftop Unit and inspect each unit for damage. Assure that
the carrier makes proper notation of any shortages or damage
on all copies of the freight bill and that he completes a Carrier
Inspection Report. Concealed damage not discovered during
unloading must be reported to the carrier within 15 days of
receipt of shipment. NOTE: It is the responsibility of the
purchaser to fi le all necessary claims with the carrier.
Storage
Upon the arrival of equipment at the job site, immediately store
units in a clean, dry area. Do not stack units. Do not remove
equipment from pallets until equipment is required for
installation.
Unit Protection
Cover rooftop units on the job site. Cap the open ends of pipes.
In areas where painting, plastering, roofi ng, or the spraying of fi reproof material has not been completed, all due precautions
must be taken to avoid physical damage to the units and
contamination by foreign material. Physical damage and
contamination may prevent proper start-up and may result
in costly equipment cleanup.
Application
Field supplied balancing dampers in duct are recommended.
Rigging Unit For Lifting
1. Maximum weight 300-1200 lbs. See Physical Data Table.
2. Remove crating.
3. All panels must be in place for rigging.
4. Remove barometric exhaust hood from door marked fi lter
access. Install barometric exhaust hood over exhaust blower
outlet.
5. Forklift channels must be removed from the base of
ERV.
6. Position unit and provide service access to ERV control
access door and wheel.
7. Duct work should be installed into roof curb before installing
ERV on curb.
8. Roof curb gasket must be applied to all top surfaces of the
curb.
9. Position unit on roof curb and provide service access to ERV
control access door and wheel.
CAUTION!
CAUTION! Danger of sharp metallic edges. Can cause
injury. Take care when servicing unit to avoid accidental
contact with sharp edges.
WARNING!
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.
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 ERV 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.
WARNING!
WARNING! To avoid equipment damage, do not use these
units as a source of heat during the construction process.
The mechanical components and fi lters used in these units
will quickly become clogged with construction dirt and debris
which may cause system damage.
WARNING!
WARNING! The installation of water-source heat pumps and
all associated components, parts, and accessories which
make up the installation shall be in accordance with the
regulations of ALL authorities having jurisdiction and MUST
conform to all applicable codes. It is the responsibility of
the installing contractor to determine and comply with ALL
applicable codes, regulations and ANSI/NFPA No. 70
CLIMATEMASTER WATER-SOURCE HEAT PUMPS
O (ERV) Series
Rev.: 04 April, 2014
This Page Intentionally Left Blank
2
ClimateMaster Water-Source Heat Pumps
THE SMART SOLUTION FOR ENERGY EFFICIENCY
O (ERV) Series
Rev.: 04 April, 2014
Figure 1
(B)
(A)
(G)
(C)
(F)
(D)
(E)
(H)
ASSEMBLED FRESH AIR HOOD
Installation
Fresh Air Hood Assembly (See Figure1)
1. Attach duct work to duct fl anges on roof curb.
2. Remove forklift channels from base of ERV.
3. Set ERV on curb. Verify ERV is positioned on curb properly.
4. Remove barometric exhaust hood from door marked fi lter
access. Install barometric exhaust hood over exhaust
blower outlet.
5. Remove ERV control access panel to connect fi eld wiring.
6. Route class II low voltage wire (3 conductor) from
thermostat or energy management through small bushing in
end panel of ERV. See wiring diagram.
a. Thermostat (dependent) - connect in parallel at rooftop
unit with “G”, “C” and “W”. Then connect matching color
at terminal 1, 2, and 3 respectively on ERV circuit board.
b. Energy Management - provide +24 VAC to “1” and
common, 24 VAC to “2” terminals on ERV circuit board.
c. Thermostat (dedicated) - splice into +24 vac (blue wire)
at (control circuit board) transformer connection run wire
to “R” terminal. Then run another wire from “G” terminal
to ERV (control circuit board) terminal block #1.
7. 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.
8. Refer to the unit nameplate for minimum circuit ampacity
(MCA) and maximum overcurrent protection size (fuse).
9. Electrical data is listed on unit rating plate and motor name
plates.
10. Connect line voltage power supply to ERV fuse block in
control box of unit from disconnect switch. See wiring
diagram.
11. 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.
12. Remove motor access panels. Locate belts fastened to
blower assembly. Install belt onto motor and blower pulley.
Adjust motor sheave to correct blower RPM for CFM and
external static pressure requirements. See charts in this
instruction. Multiple pulley arrangements are available to
meet the entire range.
CAUTION!
CAUTION! Blower speed must be adjusted for the given
external static pressure and airfl ow (CFM) requirements. If
blower speed is not adjusted for conditions, possible motor
over loading can occur.
13. Replace access panel onto the ERV unit and secure.
14. Restore power to unit.
15. Cleanup once unit is operating properly, caulk any open
joints, holes or seams to make the units completely air and
water tight.
16. Leave this instruction manual with owner or in an envelope
to be kept near unit.
Operation
(How It Works)
The unit contains an Energy Recovery Wheel (ERW) that is a
new concept in rotary air-to-air heat exchangers. Designed as a
packaged unit for ease of installation and maintenance, only the
connection of electrical power is required to make the system
operational.
When slowly rotating through counter fl owing exhaust and fresh
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3
CLIMATEMASTER WATER-SOURCE HEAT PUMPS
O (ERV) Series
Rev.: 04 April, 2014
air streams the ERW 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 50-60 revolutions per minute, the wheel provides
constant fl ow of energy from warmer to cooler air stream.
The large energy transfer surface and laminar fl ow through
the wheel causes this constant fl ow 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 signifi cant part of a humidifi cation
heat load.
During both the summer and winter, the ERW 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
ERV is always being cleaned by air, fi rst 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.
Low Ambient Kit (Optional)
Low Ambient Kit turns off the supply blower when outdoor
temperatures fall below the frost threshold. The exhaust only
thermostat set points are fi eld adjustable. Supply fan operation
is automatically restored when the exhaust air temperature rises
above the thermostat set point. Provisions for introducing makeup air into the building when the supply blower is off to avoid
depressurization should be considered.
Recovery Wheel 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 ERV.
System Check
1. Disconnect main power.
2. Turn to “Cont” for blower operation on thermostat controlled
models.
3. Restore power to unit. Observe ERV 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.
During the heating season, when outdoor air temperatures
are below 15ºF, it is recommended to use the (optional) low
ambient kit (fi eld installed).
Low Ambient Kit is appropriate for climates with limited HVAC
system operation when outdoor temperatures are below 10ºF.
The frost threshold is the outdoor temperature at which frost
will begin to form on the ERV wheel. For Energy Recovery
Ventilators, the frost threshold is typically below 10ºF. Frost
threshold is dependent on indoor temperature and humidify.
The table shows how the frost threshold temperatures vary
depending on indoor conditions.
FROST THRESHOLD TEMPERATURE
INDOOR RH AT 70ºF
FROST THRESHOLD
TEMPERATURE
20%0ºF
30%5ºF
40%10ºF
Because Energy Recovery Ventilators have a low frost
threshold, frost control options are not necessary in many
climates. Where outdoor temperatures may drop below the frost
threshold during the ERV operational hours, exhaust only frost
control option is available.
4. Verify that the ERV (3) three phase blower motors are
phased sequentially ensuring correct rotation and operation.
a. Disconnect power.
b. Reverse any two fi eld power leads to the ERV.
c. Reapply power.
5. Verify that both blower motors are operating under their
full load AMP rating (FLA). The FLA can be found on each
motor and the unit nameplate.
A. Return Damper Settings
Manually adjust position of fi eld installed dampers to
balance air fl ow.
B. Air Flow / Blower Speed Adjustment
Blower speed selection is accomplished by changing the
sheave setting on both fresh air and exhaust air blowers. To
set ERV for the required air fl ow (CFM), the external static
pressure applied to the ERV (duct static) must be known.
See the CFM vs External Static Pressure chart for the
appropriate unit to determine the correct blower RPM for
the specifi ed CFM and External Static Pressure.
After blower speed adjustments have been made. Ensure that
when the belt is replaced it is tensioned correctly. The motor
mounting plate can be adjusted to tension the belt. If using a
belt tension checker, adjust the span to the appropriate setting
and check the belt defection force. The belt defl ection force
should be between 5-8 lbs or the lowest tension at which the
4
ClimateMaster Water-Source Heat Pumps
THE SMART SOLUTION FOR ENERGY EFFICIENCY
O (ERV) Series
Rev.: 04 April, 2014
belt will not slip under peak load conditions.
1. Disconnect main power to unit before making adjustment to
economizer and/or ERV unit.
2. Replace ERV control access cover.
3. Set thermostat to normal operating position.
4. Restore power to unit.
Maintenance
1. All motors use pre-lubricated sealed bearings; no further
lubrication is necessary.
2. Make visual inspection of motors, belts and wheel rotating
bearings during routine maintenance.
3. Eight pie-shaped 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 ERV access panels (rear) and
unplug [J150 & P150] (Refer to wiring diagram in this instruction manual). Remove segment and wash with
water and/or mild detergent.
4. To install wheel segments follow steps A through E . See Figure 2. 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 fl anges. If hand pressure does not
fully seat the segment, insert the fl at 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 rotate the wheel 180º. Install the second segment
opposite the fi rst for counterbalance. Rotate the two
installed segments 90º to balance the wheel while the
third segment is installed. Rotate the wheel 180º again
to install the fourth segment opposite the third. Repeat
this sequence with the remaining four segments.
Figure 2
SEGMENT RETAINER CATCH
WHEEL RIM
E
D
SPOKE
HUB
C
B
screw on the pulley(s) to 100 in.lb.
3. Install the belt that came with the pulley kit. Tension belt as
explained in the blower speed adjustment section.
4. Check the speed of the blower. Adjust the motor sheave to
increase or decrease the speed of the blower. See blower
adjustment section.
SEGMENT RETAINER
A
D
SEGMENT
Pulley Kit Installation
The units are shipped from the factory at the low static setting.
Pulley kits are available for the medium and high static settings.
To install a pulley kit.
1. Check content of pulley kit, if pulley kit contains:
a. An adjustable sheave and a fi xed pitch pulley then
remove belt and both motor and blower pulley
b. An adjustable sheave then remove the motor pulley.
c. A fi xed pitch pulley then remove the blower pulley.
2. Replace pulley(s) with the pulley(s) from pulley kit. Make
sure each pulley is installed with a key. Tighten the set
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