Greenheck VER-65 Installation Manual

Page 1

Part #471849

Energy Recovery – VersiVent

Installation, Operation and Maintenance Manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

Model VER

General Safety Information

Only qualiﬁed personnel should install this system. Personnel should have a clear understanding of these instructions and should be aware of general safety precautions. Improper installation can result in electric shock, possible injury due to coming in contact with moving parts, as well as other potential hazards. Other considerations may be required if high winds or seismic activity are present. If more information is needed, contact a licensed professional engineer before moving forward.

DANGER

Always disconnect power before working on or near this equipment. Lock and tag the disconnect switch or breaker to prevent accidental power up.

CAUTION

When servicing the unit, the internal components may be hot enough to cause pain or injury. Allow time for cooling before servicing.

CAUTION

Precaution should be taken in explosive atmospheres.

1. Follow all local electrical and safety codes, as well as the National Electrical Code (NEC), the National Fire Protection Agency (NFPA), where applicable. Follow the Canadian Electric Code (CEC) in Canada.

2. All moving parts must be free to rotate without striking or rubbing any stationary objects.

3. Unit must be securely and adequately grounded.

4. Do not spin fan wheel faster than maximum cataloged fan RPM. Adjustments to fan speed signiﬁcantly effects motor load. If the fan RPM is changed, the motor current should be checked to make sure it is not exceeding the motor nameplate amps.

5. Do not allow the power cable to kink or come in contact with oil, grease, hot surfaces or chemicals. Replace cord immediately if damaged.

6. Verify that the power source is compatible with the equipment.

7. Never open access doors to the unit while it is running.

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Receiving

Upon receiving the product, check to make sure all items are accounted for by referencing the bill of lading to ensure all items were received. Inspect each crate for shipping damage before accepting delivery. Notify the carrier if any damage is noticed. The carrier will make notiﬁcation on the delivery receipt acknowledging any damage to the product. All damage should be noted on all the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report should be ﬁlled out by the carrier upon arrival and the Trafﬁc Department. If damaged upon arrival, ﬁle claim with carrier. Any physical damage to the unit after acceptance is not the responsibility of Greenheck Fan Corporation.

Unpacking

Verify that all required parts and the correct quantity of each item have been received. If any items are missing report shortages to your local representative to arrange for obtaining missing parts. Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space. Conﬁrmation of shipment(s) must be limited to only items on the bill of lading.

Handling

Units are to be rigged and moved by the lifting brackets provided or by the skid when a forklift is used. Location of brackets varies by model and size. Handle each piece in such a manner as to keep from scratching or chipping the coating. Damaged ﬁnish may reduce ability of the unit to resist corrosion.

Storage

Units are protected against damage during shipment. If the unit cannot be installed and operated immediately, precautions need to be taken to prevent deterioration of the unit during storage. The user assumes responsibility of the unit and accessories while in storage. The manufacturer will not be responsible for damage during storage. These suggestions are provided solely as a convenience to the user.

Inspection and Maintenance during Storage

While in storage, inspect units once per month. Keep a record of inspection and maintenance performed

If moisture or dirt accumulations are found on parts, the source should be located and eliminated. At each inspection, rotate all moving components by hand ten to ﬁfteen revolutions to distribute lubricant on motor and bearings. If paint deterioration begins, consideration should be given to touch-up or repainting. Units with special coatings may require special techniques for touch-up or repair.

Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur. Immediately remove the original rust preventive coating with petroleum solvent and clean with lint-free cloths. Polish any remaining rust from surface with crocus cloth or ﬁne emery paper and oil. Do not destroy the continuity of the surfaces. Wipe clean thoroughly with Tectyl® 506 (Ashland Inc.) or the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl® 511M Rust Preventive or WD-40® or the equivalent.

Special Owner’s Information for Units with Packaged DX

The following summary highlights some important notes to help avoid premature failure and possible voidance of warranty.

Product Overview

Greenheck VER Models integrated with a complete refrigerant system are designed with the purpose of being a self-contained source for heating and cooling in both commercial and institutional applications. This is done in a highly efﬁcient manner through the use of a total enthalpy recovery wheel. The wheel allows the compressors and cooling equipment to be downsized in the unit, therefore being more cost effective to operate. The DX system comes fully charged from the factory with refrigerant and is ready for installation upon arrival.

Units above seven (7) tons come standard with two compressors. This allows for staging of compressors to meet a wider range of outdoor air loads while reducing the amount of cycles per compressor.

Integral Components

All units are provided with an expansion valve, hermetic scroll compressor(s), liquid line ﬁlter drier, high pressure manual reset cutout, low pressure autoreset cutout, time delays for compressor protection, service/ charging valves, moisture indicating sight glass, and hot gas bypass. The compressors also come standard with a crankcase heater for additional protection.

Shutdown Operation

The scroll compressors in this unit are designed to compress gas refrigerant only. To prevent liquid refrigerant from migrating into and damaging the compressors, each compressor is supplied with a crankcase heater. Prior to starting the compressors, the heaters must have power to them for 24 hours. Power should never be cut to these units unless the complete shutdown procedure is followed.

Proper shutdown procedure:

1. Turn off main power supply to the unit

2. Turn thermostat controls to “off” position

3. Restore main power supply to the unit

4. Wait 24 hours prior to turning the thermostat control to the “on” position.

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Low Ambient Operation

Low ambient operation can cause damage to the refrigerant system. A factory-installed temperature sensor in the outdoor air intake prevents refrigerant system operation at ambient conditions below 55ºF. Crankcase heaters will still be engaged provided the main power has not been disconnected. If cooling is desired at ambient temperatures below 55ºF, economizer operation (wheel start/stop or wheel modulation) should be employed.

Reduced Airﬂow Pumping Oil and Liquid Refrigerant

Lack of maintenance will lead to ﬁlters, condensing coils, and evaporator coils building up with dirt and debris. As this occurs, the airﬂow through the unit will decrease. Cooling coils are sized to handle a particular airﬂow volume. A reduction in airﬂow can cause the cooling coils to get too cold and may result in excessive liquid refrigerant return to the compressors. The liquid refrigerant buildup in the compressors will displace the necessary oil required for proper lubrication. The combination of these two events will signiﬁcantly reduce the life of the compressors.

To maintain the proper airﬂow and system efﬁciency, follow all procedures in the Maintenance section.

Safety Listing

The VER units are listed per ANSI/UL 1995, Heating and Cooling Equipment, and bear the ETL label.

Environmental Concerns

When working with Greenheck’s fully charged refrigerant system, it is strongly recommended that caution is undertaken during installation, operation, and routine maintenance. This caution will help ensure that minimal amounts of refrigerant are leaked into the atmosphere. To comply to the U.S. Clean Air Act, anytime there is residual refrigerant, the proper equipment shall be used and methods should be followed to reclaim the refrigerant so that it can be recycled, reprocessed, or destroyed.

IMPORTANT

Do not release refrigerant to the atmosphere! If required service procedures include the adding or removing of refrigerant, the service technician must comply with all federal, state and local laws. The procedures discussed in this manual should only be performed by a qualified EPA Certified Technician.

Table of Contents

Basic Operation . . . . . . . . . . . . . . 4

Installation

Installation Concerns. . . . . . . . . . . . 4

Lifting . . . . . . . . . . . . . . . . . . 5

Recommended Roof Openings . . . . . . . 5

Unit Weights and Dimensions . . . . . . . . 6

Rail and Roof Curb Mounting

Rail Mounting and Layout . . . . . . . . . . 7

Roof Curb Mounting . . . . . . . . . . . . 7

Curb Dimensions and Weights . . . . . . . . 8

Electrical Information

General Electrical Information . . . . . . . . 9

Control Center Components . . . . . . . . . 10

Electric Heater Application/Operation . . . . . 10

Unit Accessories. . . . . . . . . . . . . . 10

Service Clearances . . . . . . . . . . . . 11

Access Panel Description. . . . . . . . . . 12

Component Location . . . . . . . . . . . . 13

Coil Applications . . . . . . . . . . . . . 14

Drain Trap Information . . . . . . . . . . . 15

Ductwork Connections . . . . . . . . . . . 15

Optional Accessories

Frost Control Application/Operation . . . . . 16

Economizer Application/Operation . . . . . . 17

Variable Frequency Drives and Wiring . . . .18 -19

Sensors and Lights . . . . . . . . . . . . 20

Sensors Mounted by Factory . . . . . . . . 21

Remote Control Panel and Wiring . . . . . . 22

Typical Wiring Diagram . . . . . . . . . 23-24

Sequence of Operation . . . . . . . . . . . 25

Start-Up

Unit . . . . . . . . . . . . . . . . . 26-28

Optional Accessories . . . . . . . . . . . 29

Fan . . . . . . . . . . . . . . . . . 30-31

Energy Recovery Wheel . . . . . . . . . . 31

Refrigeration System . . . . . . . . . . 32-33

Routine Maintenance Checklist

General . . . . . . . . . . . . . . . . . 34

Belts . . . . . . . . . . . . . . . . 34-35

Motors . . . . . . . . . . . . . . . . . 35

Fan Wheel and Fasteners . . . . . . . . . . 35

Fan Bearings . . . . . . . . . . . . . . . 35

Filters . . . . . . . . . . . . . . . . . . 36

Coil Maintenance . . . . . . . . . . . 36-37

Energy Recovery Wheel Maintenance

Accessing Energy Recovery Wheel . . . . . 37

Removing Wheel Segments . . . . . . . . 37

Cleaning Wheel Segments . . . . . . . . 37

Wheel Belts . . . . . . . . . . . . . . 37

Wheel Bearings . . . . . . . . . . . . . 37

Troubleshooting – Airflow . . . . . . . . . . 38

Troubleshooting – Unit . . . . . . . . . 39-40

Troubleshooting – Refrigeration Circuit . .41-45

Maintenance Log . . . . . . . . . . . 46-47

Warranty . . . . . . . . . . . . . Backcover

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Basic Operation

Installation

The VER units bring in fresh, outdoor air and remove stale, exhaust air. Prior to discharging the exhaust air, the energy recovery wheel transfers energy from the exhaust air to the outdoor air at an efﬁciency of 7080%. Simply put, this unit preconditions the outdoor air to save money on heating and cooling costs. These particular units also have cooling and heating options available after the recovery wheel to further condition the fresh air.

Supplemental Installation, Operation and Maintenance Manuals

Refer to the following Installation, Operation and Maintenance Manuals for additional details:

Part #463687 — Centrifugal Fan

Part #461006 — Indirect Gas-Fired Furnaces for Energy Recovery Units, Model PVF

Part #469690 — Microprocessor Controller

Installation, Operation and Maintenance Manuals can be found online at www.greenheck.com

General Installation, Operation and Maintenance (IOM) Information

The VER model energy recovery unit is designed with semi-custom versatility in mind. This quality allows for the selection of several component options. Please be aware that this IOM is comprehensive and includes information for all the potential options offered for this product line. Included options will vary on each unit. Please pay special attention to the speciﬁc unit in question when reviewing the information in this manual.

The system design and installation should follow accepted industry practice, such as described in the ASHRAE Handbook.

Adequate space should be left around the unit for piping coils and drains, ﬁlter replacement, and maintenance. Sufﬁcient space should be provided on the side of the unit for routine service and component removal should that become necessary.

See Service Clearances/Access Panel Locations section for more details.

Installation Concerns for Units with Packaged DX

Unobstructed airﬂow to the condensing section must be maintained at all times to ensure proper operating efﬁciency and capacity of the cooling system. Unit placement should allow proper airﬂow over the condensing section. The unit may not operate properly and damage may occur to the system if there is coil starvation (lack of air over condenser) or warm air recirculating back through the condensing coil. Recirculating air is caused when the unit is placed near obstacles that can redirect exhaust air from the condensing fans, back around to the coil inlet. Overhangs or walls near the condensing section are two examples.

Another consideration when placing the unit is prevailing wind direction. The condensing coil operation can be signiﬁcantly affected when winds are blowing continuously and directly at the condensing coil. On hot days, the wind will help the system by providing extra ﬂow over the coil. But on cooler days, that same wind may overcool the refrigerant, and cause hot gas bypass to operate more frequently, causing higher operating costs. Therefore, avoiding direct winds will provide a more stable operation of the system throughout the cooling season.

Lack of air over the coil can reduce efﬁciencies and affect system operation. Do not allow debris (such as leaves and trash), to accumulate on or near the unit. Keeping debris clear of the unit will ensure minimal obstruction to the coils, keeping efﬁciencies and operation closer to design. The unit typically should not operate when snow is present. In the event this is possible, make sure all snow is clear of the coil and condensing fans prior to operating the unit.

If more than one unit is being installed, make provisions so discharge air from either the condensing fans or exhaust fan of the unit do not discharge towards another unit’s intake. Also, OA intake and condensing sections should be spaced as too allow proper airﬂow to each unit helping ensure the units operate as intended.

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Where the supply or warm air duct passes thru a

Return Air Intake

Supply Air Discharge

combustible roof, a clearance of one inch must be maintained between the outside edges of the duct and combustible material in accordance with NFPA Standard 90A.

Handling Concerns for Units with Packaged DX

While this unit was constructed with quality and dependability in mind, damage still may occur during handling of the unit for installation. Exercise extreme caution to prevent any damage from occurring to the refrigerant system. This unit contains a system pressurized with refrigerant that if damaged, could leak into the atmosphere or cause bodily harm due to the extreme cold nature of expanding refrigerant. Use protective equipment such as gloves and safety glasses to minimize or prevent injury in case of a system leak during installation.

Lifting

1. Before lifting, be sure that all shipping material has been removed from unit.

2. To assist in determining rigging requirements, weights are provided in the Unit Weights & Dimensions section on page 6.

3. Unit must be lifted by all lifting lugs provided on base structure.

4. Rigger to use suitable mating hardware to attach to unit lifting lugs.

5. Spreader bar(s) must span the unit to prevent damage to the cabinet by the lift cables.

Recommended Roof Opening

Refer to weight and dimension data to determine the exact location of the section containing the outdoor air discharge opening. If the unit is equipped with an Indirect Gas Heater (IG) section the outdoor air discharge opening will be in that section; if not, it will be in the blower section. The return air intake will be consistent for all units. The dimensions of these openings and their locations are illustrated below.

VER-45 A B C D E F G H

1 56.9 4.7 51.5 15.9 26.9 42.7 3.3 11.8 2 56.9 4.7 51.5 15.9 33.8 34.1 7.4 14.4 3 56.9 4.7 51.5 15.9 33.8 34.1 35.3 14.4 4 56.9 4.7 51.5 15.9 26.9 42.7 31.2 11.8

VER-65 A B C D E F G H

1 59.9 6.3 56.1 15.9 29.9 51.9 2.7 10.3 2 59.9 6.3 56.1 15.9 30.9 49.9 7.3 7.1 3 59.9 6.3 56.1 15.9 30.9 49.9 35.2 7.1 4 59.9 6.3 56.1 15.9 29.9 51.9 30.6 10.3

VER-90 A B C D E F G H

1 77.9 4.7 99.2 15.9 33.8 61.9 2.0 12.7 2 77.9 4.7 99.2 15.9 33.8 51.9 7.5 17.7 3 77.9 4.7 99.2 15.9 33.8 51.9 35.3 17.7 4 77.9 4.7 99.2 15.9 33.8 61.9 29.9 12.7

All dimensions are in inches. IG = Indirect Gas Furnace; PDX = Packaged DX Cooling 1 = Any unit without IG and PDX.

Blower Module is at the end of the unit. 2 = Any unit with IG that does not have PDX. 3 = Any unit with IG and PDX 4 = Any unit without IG and with PDX

When cutting only duct openings, cut opening one inch (25 mm) larger than duct size to allow clearance for installation. Area enclosed by roof curb must comply with clearance to combustible materials. If the roof is constructed of combustible materials, area within the roof curb must be ventilated, left open, or covered with non-combustible material which has an “R” value of at least five. If area within curb is open, higher radiated sound levels may result.

Where the supply or warm air duct passes thru a combustible roof, a clearance of one inch must be

6. Always test-lift the unit to check for proper balance and rigging before hoisting to desired location.

7. Never lift units by weatherhoods.

8. Never lift units in windy conditions.

9. Preparation of curb and roof openings should be completed prior to lifting unit to the roof.

10. Check to be sure that gasketing has been applied to the curb prior to lifting the unit and setting on curb.

11. Do not use fork lifts for handling unit.

maintained between the outside edges of the duct and combustible material in accordance with NFPA Standard 90A. Position the unit roof opening such that the supply discharge and exhaust inlet of the unit will line up with the corresponding ductwork. Be sure to allow for the recommended service clearances when positioning opening (see Service Clearances). Do not face the outdoor air intake of the unit into prevailing wind and keep the intake away from any other exhaust fans. Likewise, position the exhaust discharge opening away from outdoor air intakes of any other equipment.

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Unit Weights & Dimensions

B CD*

EF G

Condensing Coil

Electrical Box

4-inch Final Filters

2-inch Filters

Wheel Cassette

Outdoor Air Intake

Exhaust Air Discharge

Return Air Intake

Supply Air Discharge

B CD*

EF G

Condensing Coil

Electrical Box

4-inch Final Filters

2-inch Filters

Wheel Cassette

Outdoor Air Intake

Outdoor Air Hood

Exhaust Air Discharge

Return Air Intake

Supply Air Discharge

Intake

Section

Wheel

Section

Optional

Coil Section

Blower

Section

Optional

IG Heater Section

Optional

Condensing Section

Condensing Coil

Drain Pan Connection

IG Gas Connection

Plan View

Elevation View

D1 D2 D3 D4

D* Coil Module Options

DX + EH + HGRH

E F G H I W L*

HW = Hot Water

CW = Chilled Water

DX = Direct Expansion

EH = Electric Heat

HP = Wrap-around Heat Pipe

HGRH = Hot Gas Reheat

^Weight

see

note

Unit Size

VER-45 16.381 28.146 44.627 30.159 36.159 44.159 50.275 36.312 47.571 63.964 65.851 18.780 69.987

VER-65 16.381 30.825 46.597 30.159 36.159 44.159 50.275 38.124 47.571 65.958 72.098 23.358 76.246 6300

VER-90 16.381 34.825 85.658 30.159 36.159 44.159 50.275 41.312 47.571 65.958 65.851 23.358 91.010 7250

All dimensions shown in inches. *L Sum the lengths of the appropriate modules to get the total length of the unit. ^Weight: The weights shown are a worse case scenario based on the sheet metal and component weights for the unit. These weights include sheet metal

weights added together with the largest fans, coils and heaters for the unit.

D1 D2 D3 D4

HW HW + DX CW + HP HW + CW + HP

CW HW + CW DX + HP HW + DX + HP

DX EH + CW DX + HGRH EH + DX + HP

EH EH + DX DX + HW + HGRH EH + CW + HP

A B C

(lbs.)

4900

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Rail and Roof Curb Mounting

AB CD

Return Air

Intake

Supply Air Discharge

Rails are positioned in random places. See table for proper location

Rail Mounting and Layout

• RailsdesignedtohandletheweightoftheVER

should be positioned as shown on the diagram (rails by others).

• Makesurethatrailpositioningdoesnotinterfere

with the supply air discharge opening or the return air intake opening on the VER unit.

• Railsshouldrunthewidthoftheunitandextend

beyond the unit a minimum of 12 inches on each side.

• Setunitonrails.

Isometric View

Roof Curb Mounting

Roof curb details, including duct location dimensions, are available on VER roof curb assembly instructions.

Rooftop units require curbs to be mounted first. The duct connections must be located so they will be clear of structural members of the building.

1. Factory Supplied Roof Curbs

Roof curbs are Model GKD, which are shipped in a knockdown kit (includes duct adapter) and require field assembly (by others). Assembly instructions are included with the curb.

2. Install Curb Locate curb over roof opening and fasten in place. (Refer to Recommended Roof Openings). Check that the diagonal dimensions are within ±1/8 inch of each other and adjust as necessary. For proper coil drainage and unit operation, it is important that the installation be level. Shim as required to level.

3. Install Ductwork

Installation of all ducts should be done in accordance with SMACNA and AMCA guidelines. Duct adapter provided to support ducts prior to setting the unit.

4. Set the Unit

Lift unit to a point directly above the curb and duct openings. Guide unit while lowering to align with duct openings. Roof curbs fit inside the unit base. Make sure the unit is properly seated on the curb and is level.

Side View

Unit Size A B C D

VER-45 53.3 16

VER-65 58.1 16

VER-90 105.3 16

All dimensions shown in inches. IG = Indirect Gas

CS = Condensing Section

33.8 w/IG 27 w/o IG

31.0 w/IG 30 w/o IG

33.8 w/IG 34 w/o IG

9.2 IG w/o CS; 37.1 IG w/CS

5.2 w/o IG and CS

33.1 w/o IG and w/ CS

9 IG w/o CS; 36.9 IG w/CS

4.6 w/o IG and CS

32.5 w/o IG and w/ CS

9.2 IG w/o CS; 37.1 IG w/CS

3.7 w/o IG and CS

31.6 w/o IG and w/ CS

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4-inch Final Filters

2-inch Filters

Wheel Cassette

Outdoor Air Hood

Intake

Section

Wheel

Section

Optional

Coil Section

Blower Section

Optional

IG Heater Section

Optional

Condensing Section

Condensing Coil

Drain Pan Connection IG Gas Connection

ABC* D

E F

Curb Outside Dimensions and Weights

Side of Unit

Recommended 2-inches of Insulation

Roof Curb

1 in .

2½ in.

1.195 in.

1 in .

W - 3.75 inches

L* - 3.75 inches

Elevation View

Subtract 3.75 inches from dimensions W & L* to get the outside curb dimensions.

Unit Size

A B

C1 C2 C3 C4

VER-45 28.146 44.627 30.159 36.159 44.159 50.275 36.312 47.571 27.909 69.987

VER-65 30.825 46.597 30.159 36.159 44.159 50.275 38.124 47.571 27.909 76.246 473

D E F W L*

see

note

Curb Weight^

(lbs.)

447

VER-90 34.825 85.658 30.159 36.159 44.159 50.275 41.312 47.571 27.909 91.010 621

All dimensions shown in inches. L* — Sum up the applicable section dimensions (A–F) for your unit to get the overall length. ^ — Curb weights shown are for the worst case scenario (largest curb) possible for each size unit.

C* Coil Module Options

C1 C2 C3 C4

HW HW + DX CW + HP HW + CW + HP

CW HW + CW DX + HP HW + DX + HP

DX EH + CW DX + HGRH EH + DX + HP

EH EH + DX DX + HW + HGRH EH + CW + HP

DX + EH + HGRH

HW = Hot Water EH = Electric Heat

CW = Chilled Water HP = Wrap-around Heat Pipe

DX = Direct Expansion HGRH = Hot Gas Reheat

Curb Cap Details

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Electrical Information

The unit must be electrically grounded in accordance with the current National Electrical Code, ANSI/NFPA

70. In Canada, use current CSA Standard C22.1, Canadian Electrical Code, Part 1. In addition, the installer should be aware of any local ordinances or electrical company requirements that might apply. System power wiring must be properly fused and conform to the local and national electrical codes. System power wiring is to the unit main disconnect (door interlocking disconnect switch standard on most units) or distribution block and must be compatible with the ratings on the nameplate: supply power voltage, phase, and amperage (Minimum Circuit Amps - MCA; Maximum Overcurrent Protection MOP). All wiring beyond this point has been done by the manufacturer and cannot be modiﬁed without affecting the unit’s agency / safety certiﬁcation.

If ﬁeld installing an additional disconnect switch, it is recommended that there is at least four feet of service room between the switch and system access panels. When providing or replacing fuses in a fusible disconnect, use dual element time delay fuses and size according to the rating plate.

Field Power Connection: All power and control connections should be run through the ﬂoor or side panel.

CAUTION

The VersiVent Roof lining contains high voltage wiring. To prevent electrocution do not puncture the interior or exterior panel of the roof.

If power supply is desired through bottom of unit, run the wiring through the curb, cut a hole in the cabinet bottom, and wire to the disconnect switch. Seal penetration in cabinet bottom to prevent leakage.

The electric supply to the unit must meet stringent requirements for the system to operate properly. Voltage supply and voltage imbalance between phases should be within the following tolerances.

If the power is not within these voltage tolerances, contact the power company prior to operating the system.

Voltage Supply: See voltage use range on the rating plate. Measure and record each supply leg voltage at all line disconnect switches. Readings must fall within the allowable range on the rating plate.

Voltage Imbalance: In a 3-phase system, excessive voltage imbalance between phases will cause motors to overheat and eventually fail. Maximum allowable imbalance is 2%. To determine voltage imbalance, use recorded voltage measurements in this formula.

Key: V1, V2, V3 = line voltages as measured

VA (average) = (V1 + V2 + V3) / 3

VD = Line voltage (V1, V2 or V3) that deviates farthest from average (VA)

Formula: % Voltage Imbalance = [100 x (VA-VD)] / VA

CAUTION

If any of the original wire as supplied with the appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 105ºC.

WARNING

To prevent injury or death due to electrocution or contact with moving parts, lock disconnect switch open.

For units with a gas furnace, if you turn off the power supply, turn off the gas.

Most factory supplied electrical components are pre-wired. To determine what electrical accessories require additional ﬁeld wiring, refer to the unit speciﬁc wiring diagram located on the inside of the unit control center access door. The low voltage control circuit is 24 VAC and control wiring should not exceed

0.75 ohms.

Refer to Field Control Wiring Length/Gauge table for wire length maximums for a given wire gauge.

Field Control Wiring Length/Gauge

Total

Wire Length

125 ft. 18 200 ft. 16 300 ft. 14 450 ft. 12

Minimum

Wire Gauge

Control wires should not be run inside the same conduit as that carrying the supply power. Make sure that ﬁeld supplied conduit does not interfere with access panel operation.

If wire resistance exceeds 0.75 ohms, an industrialstyle, plug-in relay should be added to the unit control center and wired in place of the remote switch (typically between terminal blocks R and G on the terminal strip (refer to Typical Control Center Components). The relay must be rated for at least 5 amps and have a 24 VAC coil. Failure to comply with these guidelines may cause motor starters to “chatter” or not pull in which can cause contactor failures and/or motor failures.

Note: Standard factory installed electric post-

heaters have their own disconnect separate from the unit disconnect. Thus, each electric post-heater requires its own separate power connection.

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Control Center Components

3 4 19

1. Main Disconnect (non-fusible, lockable)

2. Motor Starter - Exhaust Air Fan

3. Motor Starter - Supply Air Fan

4. Motor Contactor - Energy Wheel

5. 24 VAC Control Transformer

6. 24 VAC Terminal strip

7. Fuses for blower motors*

8. Grounding lug

9. Distributor block*

10. Compressor fuse blocks*

11. Compressor contactors*

12. Condensing fan contactors*

13. Compressor relay*

14. Terminal block*

15. Compressor cycle timers*

Optional Control Center Components

16. DDC controller*

17. Dirty ﬁlter pressure switches*

18. Terminal block

19. Energy recovery wheel VFD*

*Not always provided

Electric Heater Application/Operation

Factory installed electric heaters can be provided for preheat and/or post-heat. An electric preheater warms the outdoor air prior to the energy recovery wheel to prevent frosting on the wheel. An electric post-heater warms the air leaving the energy recovery wheel to a user speciﬁed discharge temperature. Electric heaters are available in 208, 230, or 460 VAC (refer to heater nameplate for voltage).

Preheaters: Preheaters are standard as two-stage step control. Step control heaters are designed with multiple stages made up of equal increments of heating capability. For example a 10 kW heater with two stages will be composed of two 5 kW stages. Preheaters are single point wired at the factory. A temperature sensor (with ﬁeld adjustable set point) is mounted in the outdoor airstream after the preheater to turn the preheater on. See Frost Control Application/Operation for typical set points. If the temperature falls below the set point and the wheel pressure drop sensor is triggered, the ﬁrst stage of the preheater will turn on. If the ﬁrst stage does not satisfy the set point, the second stage will also turn on.

The pre-heater is single point wired to the VER control center. Access to the preheater control panel is through the outdoor air intake.

Post-heaters: Post-heaters are standard as SCR control. Post-heaters are not single point wired (see Electrical Connections). A temperature sensor (with ﬁeld adjustable set point) is mounted in the outdoor airstream after the post-heater. A SCR heater provides an inﬁnitely modulating control of the heat to provide an accurate discharge temperature. A call for heat is required to turn the post-heater on.

The post-heater is not single point wired to the VER control center. Separate power must be supplied to the post-heater disconnect located in the unit control center.

VersiVent Energy Recovery Unit

Unit Accessories

Outdoor Air Weatherhood

Outdoor air weatherhood will be factory mounted.

Exhaust Weatherhood

The exhaust weatherhood is shipped separately as a kit with its own instructions.

Dampers

Backdraft dampers are always included as an integral part of the exhaust hood assemblies. Motorized outdoor air and exhaust air dampers are optional and are factory mounted (and wired) at the intake.

Page 11

Service Clearances

TRTR

ACCESS

PANEL

ACCESS

PANEL

ACCESS

PANEL

ACCESS

PANEL

ACCESS

PANEL

ACCESS

PANEL

ACCESS

PANEL

ACCESS

PANEL

ACCESS

PANEL

ACCESS

PANEL

VER-90

ONLY

VER-45, 65 and 90 units require minimum clearances for access on all sides for routine maintenance. Filter replacement, drain pan inspection and cleaning, energy wheel cassette inspection, fan bearing lubrication and belt adjustment are examples of routine maintenance that must be performed. Blower and motor assemblies, energy recovery wheel cassette, coil and ﬁlter sections are always provided with a service door or panel for proper component access. Clearances for component removal may be greater than the service clearances, refer to drawings for these dimensions.

Additional clearances for units with packaged DX

Clearances must be maintained on all sides of this unit. This especially is true with the top of this unit. Hot air is being discharged through the condensing fans during operation, and the more clearance available, the better the chance of avoiding recirculation or coil starvation. This unit should never be placed under an overhang or inside a building. A minimum of 48 inches over the condensing fans is recommended.

Minimum 48 inches clearance

Minimum 24 inches

Condensing Coil Intake

clearance

Keep this area clear

Unit Clearances

Unit Size A B C D

VER-45 65 42 36 24

VER-65 70 42 36 24

VER-90 65 42 65 24

All dimensions shown in inches.

Access Panels may change depending on options selected.

VersiVent Energy Recovery Unit

Page 12

Access Panel Descriptions and Locations

Following is a list of items accessible through the access doors shown on the diagrams. Some items are optional and may not have been provided.

#8 – Supply Blower

#9 – Compressors

#6 – Control Panel

#2 – OA Intake Damper

and Electric Preheat

#7 – IG Furnace

Control Center

1. Aluminum mesh ﬁlters (intake hood)

2. Outdoor air intake damper Electric pre-heater

3. Exhaust blower, motor, and drives

4. Energy recovery wheel, motor, belt, and seals Exhaust air ﬁlters Exhaust air intake damper (optional) Outdoor air ﬁlters Frost control sensors (optional) Economizer sensors (optional)

5. Coil access / drain pan / ﬁnal ﬁlters Bypass damper (optional)

#5 – Packaged DX

Coil and Final Filter

#3 – Exhaust Blower

#4 – Filter & Wheel

6. Control center All electrical controls VFD for energy recovery wheel (optional)

7. Indirect gas furnace control center

8. Outdoor air blower, motor, and drives (with indirect gas furnace) Electric post-heater control center (optional)

9. Compressor(s) – refer to Refrigeration System Section for components in compressor compartment (optional)

VersiVent Energy Recovery Unit

Page 13

Component Location

1. Supply blower

  •Plenumfan   •Adjustablemotormountforbelttensioning   •Adjustablesheavesforspeedcontrol

2. Removable energy recovery wheel segments

3. Energy recovery wheel cassette

  •OnewheelformodelVER-45andVER-65   •TwowheelsformodelVER-90

4. Optional supply weatherhood with 2 inch aluminum mesh filter

5. Optional Electric Preheat Frost Control

6. Optional supply and exhaust air filter racks for 2-inch MERV 8, 30% efficient

7. Optional Final Filters

  •2-inchMERV8 30%efficient   •4-inchMERV11 65%efficient   •4-inchMERV13 85%efficient

8. Coil section optional equipment.

Not all items depicted above.

  •PackagedorsplitDXcoolingcoil–DX   •Hotgasreheatcoil–HGRH   •Chilledwatercoil–CW   •Wraparoundheatpipe–HP   •Hotwatercoil–HW   •Electricheat–EH   •Indirectgasfurnace–IG;locateddownstream

of Plenum Supply Fan

9. Vibration isolators (quantity 4 per blower)

  •SpringIsolators—SupplyFan   •NeopreneIsolators—ExhaustFan(not shown)

10. Compressor(s)

11. Condensing coil

12. Condensing fans

VersiVent Energy Recovery Unit

Page 14

Coil Application Recommendation for Units with Heating or Cooling Options

Factory installed cooling and heating components are mounted in the coil section of the unit. The coil section is downstream of the energy wheel on the supply air side of the unit.

Note the coil connection locations on the picture. Coil connections are located external to the unit as shown. Coil connections that are not external have been ordered from the factory with interior coil connections.

Note: DX coil liquid connection is internal to units.

Water Coils

1. Piping should be in accordance with accepted industry standards. Pipework should be supported independently of the coils. Water connections are male NPT iron pipe. When installing couplings, do not apply undue stress to the connection extending through the unit. Use a backup pipe wrench to avoid breaking the weld between coil connection and header.

2. Connect the water supply to the bottom connection on the air leaving side and the water return to the top connection on the air entering side. To insure proper venting, an external air vent in the piping is recommended. Connecting the supply and/or return in any other manner will result in very poor performance. Be sure to replace factory installed grommets around coil connections if removed for piping. Failure to replace grommets will result in water leakage into the unit and altered performance.

3. The air vent at the uppermost point should be temporarily opened during system start-up to release all of the air from the coil. To maintain heat transfer capacity, periodically vent any air in coil.

4. Water coils are not normally recommended for use with entering air temperatures below 40ºF; however, the energy recovery wheel maintains a pre-coil temperature higher than 40ºF. No control system can be depended on to be 100% safe against freeze-up with water coils. Glycol solutions or brines are the only safe media for operation of water coils with low entering air conditions.

Continuous water circulation through the coil at all

times is highly recommended.

5. Pipe sizes for the system must be selected on the

Water

Coil

Connections

basis of the head (pressure) available from the circulation pump. The velocity should not exceed 6 feet per second and the friction loss should be approximately 3 feet of water column per 100 feet of pipe.

6. For chilled water coils, the condensate drain pipe should be sized adequately to ensure the condensate drains properly. Refer to Drain Trap section.

Direct Expansion (DX) Coils for units with a split DX System

1. Piping should be in accordance with accepted industry standards. Pipework should be supported independently of the coils. Undue stress should not be applied at the connection to coil headers.

2. When connecting suction and liquid connections, make sure the coil is free from all foreign material. Make sure all joints are tight and free of leakage. Be sure to replace factory installed grommets around coil connections if removed for piping.

Direct Expansion (DX) Coil for units with Packaged DX System

1. The condensate drain pipe should be sized adequately to ensure the condensate drains properly. Refer to Drain Trap section.

VersiVent Energy Recovery Unit

Page 15

Length of Straight Duct

GOOD

POOR

GOODPOOR

Tu rning

Vanes

POOR

GOODPOOR

Tu rning

Vanes

Drain Trap

4 in.

2 in.

Ductwork Connections

Cooling coils are provided with a stainless steel drain pan with 1-inch male NPT drain connection. A drain trap must be connected to the drain connection to allow excess water to ﬂow out of the drain pan. More importantly, though, due to the negative internal static of the cooling coil compartment, installing the drain trap prevents outdoor air from being pulled into the drain pan and consequently forcing water out of the pan and into the unit.

To ensure the drain trap works properly, the trap height must account for the difference in static pressure between ambient conditions outside the unit and the internal negative pressure of the cooling coil compartment. For energy recovery units, an assumption of 3.0 in. wg differential will be sufﬁcient. This would require a trap design as shown. If the internal static is believed to be higher, consult factory.

Supply Fan:

The supply fan in this unit is a plenum style fan. The discharge opening dimensions are provided. For proper fan performance, match the duct size to the dimensions listed. Installation of all ducts should be done in accordance with SMACNA.

Supply Fan Discharge Opening Dimensions

Supply Air

Model

Discharge Location

Top End Bottom

VER-45 38.5 x 30 41.8 x 27

VER-65 50 x 31 50 x 31

VER-90 62 x 34 59.7 x 35

All dimensions shown in inches.

See diagram in Recommended Roof Openings section (page 5)

for the Bottom Discharge opening sizes.

Length of

Straight Duct

(Supply Fan)

Exhaust Fan

The exhaust fan in this unit is a forward curved fan. Good and Poor fan-to-duct connections are shown below. Airﬂow out of the fan should be directed strait or curved the same direction as the fan wheel rotates. Poor duct installation will result in low airﬂow and other system effects.

Refer to local codes to determine drainage requirements. If draining onto to roof, place a drip pad below drain to protect roof. If draining onto roof is not acceptable, a drain line must be attached to the trap. The drain line must be pitched away from the unit at least 1/8-in. per foot. On longer runs, an air break should be used to ensure proper drainage. Local codes may require drainage into a waste water system.

Drainage problems not only occur from improper drain trap design, but also from lack of maintenance of the cooling coil compartment. Algae can form in the drain pan and trap and cause reduced water ﬂow, which can in turn result in backup into the system. Regular maintenance will prevent this from occurring. If the drains have a clean-out opening, be sure to close the opening after cleaning.

Recommended Exhaust Fan Discharge Duct Size

Length of

Straight Duct

(Exhaust Fan)

Model Duct Size

Exhaust

Blower Size

VER-45 20 x 20 12 48

VER-65 28 x 28 15 60

VER-90 32 x 32 18 60

All dimensions shown in inches.

• Recommendedductsizesarebasedonvelocitiesacrossthe

cfm range of each model at approximately 800 feet per minute (FPM) at minimum airflow and up to 1600 fpm at maximum airflow. Recommended duct sizes are only intended to be a guide and may not satisfy the requirements of the project. Refer to plans for appropriate job specific duct size and/or velocity limitations.

• Straightductlengthswerecalculatedbasedon100%effective

duct length requirements as prescribed in AMCA Publication

201. Calculated values have been rounded up to nearest foot.

VersiVent Energy Recovery Unit

Page 16

A1 B1 15

16 18 A2

0.20

0.41.0

0.60.8

0.20

0.41.0

0.60.8

T21 MIN

T11 MIN

Timer Scale

Dip Switch

Optional Accessories

Frost Control Application/Operation

Extremely cold outdoor air temperatures can cause moisture condensation and frosting on the energy recovery wheel. Frost control is an optional feature that will prevent/control wheel frosting. Three options are available:

1. Timed Exhaust frost control

2. Electric preheat frost control

3. Modulating wheel frost control All of these options are provided with a thermostat

(with probe) mounted in the outdoor air intake compartment and a pressure sensor to monitor pressure drop across the wheel.

Frost Threshold Temperatures

Indoor RH @ 70°F Frost Threshold Temp

20% -10º F

30% -5º F

40% 0º F

The typical temperature setting corresponds to the indoor air relative humidity as shown in the Frost Threshold Temperatures Table and represents when frost can occur. An increase in pressure drop would indicate that frost is occurring. Both the pressure sensor AND the outdoor air temperature sensor must trigger in order to initiate frost control. The two sensors together insure that frost control is only initiated during a real frost condition. Field wiring of a light (or other alarm) between 6 & C in the control center will notify personnel when unit is in frost control mode (refer to Remote Panel Wiring schematics section for wiring details). The following explains the three options in more detail.

Timed exhaust frost control includes a timer in addition to the thermostat and wheel pressure sensor. When timed exhaust frost control is initiated, the timer will turn the supply blower on and off to allow the warm exhaust air to defrost the energy recovery wheel. Default factory settings are 5 minutes off and 30 minutes on. Use the following test procedure for troubleshooting.

Testing (refer to Timer Faceplate drawing below)

• Jumperthewheelpressureswitchintheunit

control center. Set the Timer Scale for T1 and T2 to 1 minute. Set the Timer Settings for T1 and T2 to

1.0. Set the dip switch to the down position. (normal position)

• Turnthetemperature

sensor up as high as possible. The supply blower should cycle on for one minute, then turn off for one minute.

VersiVent Energy Recovery Unit

• Aftertesting,settheTimerScaleasfollows: T1 = 10 minutes, T2 = 1 hour

• SettheTimerSettingsasfollows: T1 = 0.5, T2 = 0.5 The timer is now set for 5 minutes off and 30 minutes on. Remember to remove the jumper.

Electric preheat frost control includes an electric heater (at outdoor air intake) and an airﬂow pressure switch (located at the preheater) in addition to the thermostat and pressure sensor on wheel. (Refer to Electric Heater Application/Operation for electric preheater location). When electric preheat frost control is initiated, the electric preheater will turn on and warm the air entering the energy wheel to avoid frosting. Use the following test procedure for troubleshooting.

Testing:

• Turnthethermostatashighasitwillgoand

jumper the wheel pressure sensor. The heater should turn on.

• Ifitdoesn’t,eitherputtheoutdoorairsidedoors

on or temporarily jumper the airﬂow pressure switch in the preheater control center to avoid nuisance tripping of the pressure switch. Also check the airﬂow switch pressure tap located at the supply discharge blower to ensure the tubing is connected and the tap is not blocked.

Remember to remove the jumpers.

Modulating wheel frost control includes a variable frequency drive in addition to the thermostat and pressure sensor. When modulating wheel frost control is initiated, the variable frequency drive will reduce the speed of the wheel. Reducing the speed of the energy wheel reduces its effectiveness, which keeps the exhaust air condition from reaching saturation, thus, eliminating condensation and frosting. If the outdoor air temperature is greater than the frost threshold temperature OR the pressure differential is less than the set point, the wheel will run at full speed. If the outdoor air temperature is less than the frost threshold temperature AND the pressure differential is greater than the set point, the wheel will run at reduced speed until the pressure differential falls below the set point. The temperature and pressure differential set points are set at the factory, but are ﬁeld-adjustable (refer to VFD section for more information). The variable frequency drive will be fully programmed at the factory.

Page 17

Economizer Application/Operation

The energy recovery wheel operation can be altered to take advantage of economizer operation (free cooling). Two modes are available:

1. De-energizing the wheel

2. Modulating the wheel

Both modes above require a ﬁeld supplied call for cool (R to Y1) in order to be activated.

De-energizing the wheel is accomplished with a signal from a Temperature or Enthalpy sensor mounted in the air intake compartment. This primary sensor will de-energize the energy wheel when the outdoor air temperature (factory default is 65ºF) or enthalpy (factory default is the ‘D’ setting) is below the ﬁeld adjustable set point. An Override temperature sensor is also furnished in the outdoor air intake compartment to deactivate economizer mode. The Override (with ﬁeld adjustable set point) is set at some temperature lower than the primary sensor (factory default is 50ºF). Effectively, the two sensors create a deadband where the energy recovery wheel will not operate and free cooling from outside can be brought into the building unconditioned.

Testing

Temperature Sensor with Override

• TurnbothTemperatureand

Override thermostats down as low as they go. The wheel should be rotating.

• TurntheTemperatureSensor

up as high as it goes, and keep the Override sensor as low as it will go. The wheel should stop rotating.

• Turnbothsensorsashighastheywillgo.The

wheel should start rotating.

• SettheTemperatureSensoratdesiredpoint

for economizer operation to begin. Set the Override sensor at desired point for economizer operation to end (factory default is 65ºF and 50ºF, respectively).

Enthalpy Sensor with Override

• Turnunitpoweroff.Disconnect

C7400 Solid State Enthalpy Sensor from terminal So on the enthalpy controller. Also, disconnect the

620 ohm resistor from terminal Sr on the enthalpy controller. Turn unit power on. The LED on the enthalpy controller should light and the energy recovery wheel should not rotate.

•Turnunitpoweroff.Reconnect620

ohm resistor to terminal Sr on the

Enthalpy

enthalpy controller. Turn unit power

Controller

Temperature

Sensor with

Override

Enthalpy

Sensor with

Override

on. The LED on the enthalpy controller should not light and the energy recovery wheel should energize and rotate.

If these steps provide the results described, the enthalpy economizer is working properly.

• Turnunitpoweroff.ReconnectC7400solidstate

enthalpy sensor to terminal So.

Modulating the Wheel

In applications in which an internal heat gain is present in the space, the rotational speed of the energy wheel may be modulated (via variable frequency drive) to avoid overheating the space during the winter. The speed of the energy wheel will be controlled in response to the discharge temperature set point.

Sequence of Operation: The variable frequency drive is fully programmed at the factory (refer to VFD section for more information). A “call for cool” must be ﬁeld wired to the unit (terminals provided in unit - refer to wiring diagram in unit control center) to allow for initiation of economizer mode. When the space calls for cooling, factory supplied controls will drive the following wheel operations:

TAO > T

TAO < T

and

TAO > T

TAO < T

and

TAO < T

Wheel runs at full speed.

(maximum energy recovery)

Wheel is stopped.

(no energy recovery)

Wheel will modulate to maintain

discharge temperature.

Where (TOA) is the outdoor air temperature set point, (TRA) is the return air temperature set point, and (TSA) is the supply air discharge thermostat set point.

VersiVent Energy Recovery Unit

Page 18

Variable Frequency Drives for Energy Recovery Blowers

MA MB MCRPH1SCHCS7S6S5S4S3S2S1

MPACAMAC+VA2A1PCP2P1

IGS-S+R-R+

V1000

MA MB MCACAMAC+VA1SCS5S4S3S2S1

J1000

OPTION 1 - 0-10 VDC CONTROL

SEE VFD INSTALLATION MANUAL FOR MORE DETAIL

USER TO PROVIDE ISOLATION AS REQUIRED

FOR CONTINUOUS 60Hz OPERATION JUMPER TERMINALS A1 AND +V.

WIRED TO A1 (+) AND AC (COMMON)

0-10 VDC CONTROL SIGNAL (BY OTHERS)

10 VDC=60 Hz

0 VDC=30 Hz

A1 AC

FOR ONE 0-10 SIGNAL, WIRE TO DRIVES IN PARALLEL

OPTION 2 - MULTI SPEED CONTROL

S5S4 SC

NEITHER S4 OR S5 CONTACT CLOSED DRIVE SPEED = 60 Hz.

DRIVE SPEED = 40 Hz.

S4 TO SC CONTACT CLOSED (BY OTHERS)

S5 TO SC CONTACT CLOSED (BY OTHERS) DRIVE SPEED = 30 Hz.

TO CHANGE THE FACTORY SET Hz CHANGE THE FOLLOWING PARAMETERS.

PARAMETER n01 CHANGE TO 1

PARAMETER n22 FOR NEW 40Hz SETTING

PARAMETER n21 FOR NEW 60Hz SETTING

PARAMETER n23 FOR NEW 30Hz SETTING PARAMETER n01 CHANGE TO 0

USER TO PROVIDE CONTACTS AND ISOLATION AS REQUIRED

SEE VFD INSTALLATION MANUAL FOR MORE DETAIL

Optional factory installed, wired, and programmed variable frequency drives (VFDs) may have been provided for modulating or multi-speed control of the blowers. One VFD is provided for each blower (supply air and

exhaust).TheVFD’sprovidedareeitherYaskawamodelV1000orJ1000.Refertothetablesinthissectionfor

factory settings and ﬁeld wiring requirements. Refer to the unit control center for unit speciﬁc wiring diagram (an example wiring diagram has been provided in this manual for reference). When making adjustments outside of the factory set points, refer to Yaskawa VFD instruction manual, which can be found online at www.drives.com. For technical support, contact Yaskawa direct at 1-800-927-5292.

VersiVent Energy Recovery Unit

Factory Set Points

Variable Frequency Drives (VFDs) for the blowers are factory setup to operate in one of the three following modes:

Modulating: 0-10 VDC signal wired in the ﬁeld by

others varies the speed of the blower between 30 and 60Hz

Multi-speed: Digital contact closures by others

command the VFD to run at multiple speed settings:

 •SCtoS4-Driverunsat40Hz  •SCtoS5-Driverunsat30Hz

CO2 Sensor: A digital contact closure from an

optional factory provided CO2 sensor sends the VFD to high or low speed depending on CO2 ppm levels at the sensor.

The terminal locations for Modulating (option 1) and Multi-speed (option 2) are shown on the left. Most of the set points in the VFDs are Yaskawa factory defaults. However, a few set points are changed at Greenheck and are shown in the tables on the next page. These settings are based on the VFD mode selected.

To gain access to change set points on the V1000 and

J1000drives,parameterA1-01needstobesetat“2”.

To prevent access or tampering with drive settings on either drive, change parameter A1-01 to “0”.

Drive Operation

SC to S1 contact for On/Off

A1 (0-10 VDC) referenced to AC. Can use +15 VDC

from +V

Page 19

Factory Set Points - continued

Resetting the V1000 drive to factory defaults

To reset the V1000 drive back to Greenheck factory defaults go to parameter A1-01 and set it to “2”. Then go to A1-03 and change it to “1110” and press enter. The drive is now reset back to the settings programmed at Greenheck. This option is not

availableontheJ1000.

MODULATING CONTROL FOR FAN SPEED

(0-10 VDC)

Parameter

A1-01 Access Level 2 2

b1-17 VFD Start-Up Setting 1 1 C1-01 Acceleration Time 30 sec. 30 sec. C1-02 Deceleration Time 30 sec. 30 sec. C6-02 Carrier Frequency 1 1

d2-02 Ref Lower Limit 50% 50%

E2-01 Motor Rated FLA

H3-04 Terminal A1 Bias 50% 50% A1-01 Access Level 0 0

MULTI-SPEED CONTROL FOR FAN SPEED

(1/3 OR 1/2 SPEED REDUCTION)

Parameter

A1-01 Access Level 2 2

b1-01 Reference Source (Frequency) 0 0

b1-17 VFD Start-Up Setting 1 1

C1-01 Acceleration Time 30 sec. 30 sec.

C1-02 Deceleration Time 30 sec. 30 sec.

C6-02 Carrier Frequency 1 1

d1-01 Frequency Reference 1 60 Hz 60 Hz

d1-02 Frequency Reference 2 40 Hz 40 Hz

d1-03 Frequency Reference 3 30 Hz 30 Hz

d1-04 Frequency Reference 4 60 Hz 60 Hz

d2-02 Ref Lower Limit 50% 50%

E2-01 Motor Rated FLA

H1-04

H1-05

H1-06

H3-10 A2 Not Used F NA

A1-01 Access Level 0 0

Multi-Function Input Sel 4

(Terminal S4)

Multi-Function Input Sel 5

(Terminal S5)

Multi-Function Input Sel 6

(Terminal S6)

Setting

V1000 J1000

Motor

FLA

V1000 J1000

Motor

FLA

3 3

4 4

5 NA

Motor

FLA

Setting

Motor

FLA

CO2 SENSOR CONTROL FOR FAN SPEED

(1/2 SPEED WHEN C02 DROPS bELOW 700 PPM)

(FULL SPEED WHEN C02 RISES AbOVE 800 PPM)

Parameter

A1-01 Access Level 2 2

b1-01 Reference Source (Frequency) 0 0

b1-17 VFD Start-Up Setting 1 1

C1-01 Acceleration Time 30 sec. 30 sec.

C1-02 Deceleration Time 30 sec. 30 sec.

C6-02 Carrier Frequency 1 1

d1-01 Frequency Reference 1 60 Hz 30 Hz

d1-02 Frequency Reference 2 30 Hz 60 Hz

d2-02 Ref Lower Limit 50% 50%

E2-01 Motor Rated FLA

H3-10 A2 Not Used F NA

A1-01 Access Level 0 0

Setting

V1000 J1000

Motor

FLA

Motor

FLA

Variable Frequency Drives for Energy Recovery Wheel

Optional factory installed VFD for the energy recovery wheel is programmed at the factory per the settings shown below for economizer and frost control modes.

TheVFDprovidedisaYaskawamodelJ1000.Refer

to the VFD instruction manual that ships with the unit when making adjustments.

Parameter Setting–J1000 A1-01 Access Level 2 b1-17 VFD Auto Start 1 C6-02 Carrier Frequency 2 d2-01 Ref Upper Limit 100% or 66%* d2-02 Ref Lower Limit 5% E2-01 Motor Rated FLA Motor FLA

E2-03 Motor No-Load Current

H1-02

H2-01

Multi-Function Input

(Terminal S2)

Multi-Function Output

(MA, MB, MC)

Economizer Signal Source (0-10 VDC)

H3-03

H3-04

L1-01 Elect Thermal Overload 2 L4-01 Frequency Detection Level 20 A1-01 Access Level 0

*36 inch wheel is 66% (40 Hz). All other wheels are 100% (60 Hz).

Analog Frequency Reference

(Gain)

Analog Frequency Reference

(Bias)

Must be less than

FLA

Setting

Honeywell

Module

0 100

99 0

Carel

Controller

VersiVent Energy Recovery Unit

Page 20

Rotation Sensor

The rotation sensor monitors energy recovery wheel rotation. If the wheel should stop rotating, the sensor will close a set of contacts in the unit control center. Field wiring of a light (or other alarm) between terminals R & 12 in the unit control center will notify maintenance personnel when a failure has occurred (refer to Remote Panel Wiring Schematics section for wiring details).

Dirty Filter Sensor

Dirty ﬁlter sensors monitor pressure drop across the outdoor air ﬁlters, exhaust air ﬁlters or both. If the pressure drop across the ﬁlters exceeds the set point, the sensor will close a set of contacts in the unit control center. Field wiring of a light (or other alarm) to these contacts will notify maintenance personnel when ﬁlters need to be replaced.

The switch has not been set at the factory due to external system losses that will affect the switch. This switch will need minor ﬁeld adjustments after the unit has been installed with all ductwork complete. The dirty ﬁlter switch is mounted in the exhaust inlet compartment next to the unit control center or in unit control center.

To adjust the switch, the unit must be running with all of the access doors in place, except for the compartment where the switch is located (exhaust intake compartment). The adjusting screw is located on the top of the switch. Open the ﬁlter compartment and place a sheet of plastic or cardboard over 50% of the ﬁlter media. Replace the ﬁlter compartment door. Check to see if there is power at the alert signal leads (refer to electrical diagram). Whether there is power or not, turn the adjustment screw on the dirty ﬁlter gauge (clockwise if you did not have power, counterclockwise if you did have power) until the power comes on or just before the power goes off. Open the ﬁlter compartment and remove the obstructing material. Replace the door and check to make sure that you do not have power at the alert signal leads. The unit is now ready for operation.

Setscrew (on front of switch) must be manually adjusted after the system is in operation.

Negative pressure connection is toward the ‘front or top’ of the switch. (senses blower side

of ﬁlters)

DDC Temperature Control Package

Temperature control package allows for stand-alone operation of energy recovery units provided with supplemental cooling and heating. Controller can be ordered for discharge or room control. Room control would require a room thermostat (or other call for heat or cool) be wired to the controller. A remote panel option is also available to allow set points and other controller parameters to be adjusted from a remote location. For additional information, refer to the controls catalog and Installation, Operation and Maintenance Manual.

CO2 Sensor

This accessory is often used to provide a modulating control signal to a variable frequency drive to raise and lower airﬂow in relationship to the CO2 levels in the space. This strategy is often referred to as Demand Control Ventilation and provides further energy savings to the system. Follow instructions supplied with sensor for installation and wiring details.

Service Outlet

120 VAC GFCI service outlet ships loose for ﬁeld installation. Requires separate power source so power is available when unit main disconnect is turned off for servicing.

Vapor Tight Lights

Vapor tight lights provide light in the energy recovery unit. The lights are wired to a junction box mounted on the outside of the unit. The switch to turn the lights on is located in the unit control center. The switch requires a separate power source to allow for power to the lights when the unit main disconnect is off for servicing.

Positive pressure connection is toward the ‘back or bottom’ of the switch. (senses air inlet side of ﬁlters)

VersiVent Energy Recovery Unit

Page 21

Sensors Mounted by Factory

OAF-P

OAI

FROM

OUTSIDE

FILTER

OAW-P

OAAW

COOL

COIL

ACC

HEAT COIL

OAF-A

SUPPLY

BLOWER

OAD

INSIDE

OUTSIDE

EF-A

EXHAUST

BLOWER

EAW

EW-P

RAI

RAF-P

FILTER

FROM INSIDE

ENERGY WHEEL

Factory mounted temperature, pressure, and current sensors are available in the locations indicated on the unit diagram below. A list of available sensors is shown below. The speciﬁc sensors provided on a given unit are labeled in the unit control center on the terminal strip. Sensors are wired to the terminal strip to make it easy for the controls contractor to connect the Building Management System for monitoring purposes.

Temperature Sensors - 1K Ohm RTD

Drawing Labels Terminal Strip Labels

OAI OA/Supply Inlet Temp OAAW OA After Wheel ACC After Cooling Coil Temp OAD Supply Discharge Temp EAW Exhaust After Wheel Temp

Pressure Sensors (analog or digital)

Drawing Labels Terminal Strip Labels

OAF-P OA/Supply Filter Pressure OAW-P Outdoor Air Wheel Pressure RAF-P RA/Exhaust Filter Pressure EW-P Exhaust Wheel Pressure

Amp - Current Sensors (analog or digital)

Drawing Labels Terminal Strip Labels

OAF-A Supply Fan Amps EF-A Exhaust Fan Amps

VersiVent Energy Recovery Unit

Page 22

Remote Control Panel and Wiring

Unit On/Off

Econ/First Stage Cooling

Second Stage Cooling

Heat

Night Setback Timer

Night Setback Switch

Terminal Block

in unit

Control Center

7-Day Timer

S1 - Unit On/Off

Terminal Block

in Unit

Control Center

On Off

BMS

Auto

Terminal Block

in unit

Control Center

NC NO

Dirty Filter

Rotation Sensor

Frost Control

Unit On/Off

Economizer

PS2

PS3

Dirty Filter

PS2

PS3

Hot

Schematics

The remote panel is available with a number of different alarm lights and switches to control the unit. The remote panel ships loose and requires mounting and wiring in the ﬁeld.

The remote panel is available with the following options:

 • Uniton/offswitch  • Uniton/offlight  • 7-daytimeclock  • Hand/off/autoswitch  • Dirtylterlight  • Economizerlight  • Frostcontrollight  • Wheelrotationsensorlight

Refer to Electrical Connections section for Field Control Wiring recommendations.

Indicator Lights powered by the VER Unit

7-Day Timer or On/Off Switch

Dirty Filter Indicator (power by others)

For 7-Day Timer, use blue and black wires. Red wires should be capped off.

Refer to Pressure Switch for voltage and load ratings.

Hand/Off/Auto Switch

Heating/Cooling Switch & Night Setback Switch/Timer

Hand/Off/Auto Switch allows the unit to “Off” - off “On” - Manual Operation “Auto” - Unit is controlled by BMS, RTU, etc.

NOTE: RTU controllers are by others.

VersiVent Energy Recovery Unit

Page 23

Wiring Diagram

ENERGY WHEEL

FA CTORY SUPPLIED AND WIRED

MULTI-VOLTAGE PRIMARY 24 SECONDARY

TR1

TO UNIT

MAIN POWER

DS1

SUPPLY DAMPER

ENERGY WHEEL

PS1

NO C COM NO

TS1

FROST CONTROL

A1T1A2

LEGEND

C1 COOLING STAGE 1 RELAY C2 COOLING STAGE 2 RELAY CC COMPRESSOR CONTACTOR CF CONDENSING FAN CONTACTOR CH COMPRESSOR SUMP HEATER D DAMPER DB POWER DISTRIBUTION BLOCK DL DAMPER LIMIT SWITCH DS DISCONNECT SWITCH EC ECONOMIZER CONTROLLER FCS CONDENSOR F A N CYCLE SWITCH FU FUSES FU5 CONTROL TRANSFORMER FUSES (NOT ON CLASS II) FZ1 FREEZE PROTECTION HG HOT GAS REHEAT VA L V E HPS HIGH PRESSURE SWITCH (MANUAL RESET) LPS LOW PRESSURE SWITCH PS1 WHEEL FROST PRESSURE SWITCH PS2 SUPPLY DIRTY FILTER PRESSURE SWITCH PS3 EXHAUST DIRTY FILTER PRESSURE SWITCH R1 ENERGY WHEEL RELAY/CONTACTOR R2 OCCUPIED/UNOCCUPIED RELAY R3 EXHAUST BLOWER VFD RELAY R4 SUPPLY BLOWER VFD RELAY R5 MODULATING WHEEL FROST CONTROL RELAY R6 ECONOMIZER RELAY R7 COMPRESSOR INTERLOCK RELAY R8 EVAP RELAY (INDIRECT) R9 EVAP RELAY (DIRECT) R10 UNIT RELAY R11 POST HEAT RELAY R12 DEHUMIDIFICATION RELAY R13 ROOM CALL FOR HEAT RELAY R14 ROT A T ION SENSOR RELAY R15 ROT A T ION SENSOR RELAY S1 FAN SWITCH S2 ROTA T ION SENSOR (LOCATED BY WHEEL) S3 ROTA T ION SENSOR (LOCATED BY WHEEL) S4 CALL FOR HEAT SWITCH S5 OCC/UNOCC SWITCH - CLOSED=OCCUPIED/OPEN=UNOCCUPIED S6 CALL FOR COOL SWITCH (FIRST STAGE) S7 CALL FOR COOL SWITCH (SECOND STAGE) S8 CALL FOR DEHUMIDIFICATION SWITCH ST MOTOR STARTER T1 FROST CONTROL TIMER TYPICAL SETTINGS t1(OFF) = 5 MIN., t2(ON) = 30 MIN. T4 ECONOMIZER WHEEL JOG TIMER TYPICAL SETTINGS t1(OFF) = 3 HRS., t2(ON) = 10 SEC. T5 EVAP DELAY OFF TIMER T6 COMPRESSOR MINIMUM OFF TIMER (TYP. 3 MIN.) T7 COMPRESSOR MINIMUM OFF TIMER (TYP. 3 MIN.) TR TRANSFORMER TS1 FROST CONTROL THERMOST A T (JUMPER - HEAT) CLOSES ON TEMP. DECREASE TYPICAL SETTING 5°F. TS2 ECONOMIZER LOW LIMIT THERMOST A T (JUMPER - HEAT) OPENS ON TEMP . DECREASE TYP. SETTING 20° OFFSET OR 50°F> TS3 ECONOMIZER UPPER LIMIT THERMOST A T (JUMPER - HEAT) CLOSES ON TEMP. DECREASE TYP. SETTING 65°F./2° DIFF. TS4 ROOM OVERRIDE SENSOR TS5 INLET AIR POST HEATER LOCKOUT THERMOST A T (AFTER WHEEL) CLOSES ON TEMP. DECREASE TYPICAL SETTING 65°F. TS6 INLET AIR COMPRESSOR LOCKOUT THERMOST A T (JUMPER-HEAT) OPENS ON TEMP . DECREASE TYPICAL SETTING 60°F./2° DIFF.

A2 A1

o FIELD WIRED

FIELD CONTROL WIRING RESISTANCE SHOULD NOT EXCEED 0.75 OHM. IF RESISTANCE EXCEEDS 0.75 OHM THEN CONSULT FACTORY. USE 14 GAUGE MINIMUM WIRE THICKNESS FOR CONTROL WIRING.

REPLACEMENT FUSES: MUST HAVE A MINIMUM I.R. RATING OF 5 KA

CAUTION:

UNIT SHALL BE GROUND IN ACCORDANCE WITH N.E.C. POWER MUST BE OFF WHILE SERVICING.

* *

EXHAUST DAMPER

GROUND

FROST CONTROL INDICAT OR

6 C

ROTA TION INDICA T OR

12 C

USER INTERFACE CONNECTIONS:

USER TO VERIFY THAT TR1 CAN HANDLE THE VA LOAD OF INDICA T OR DEVICES.

EXHAUST FA N

SUPPLY FAN

ST2

O.L.

MOTOR

ST1

O.L.

MOTOR(S)

ST1 O.L.

95 96

ST2 O.L.

95 96

ST1

A2 A1

ST2

A2 A1

SUPPLY FAN

EXHAUST FA N

ST2

13 14

CC2-NO

FCS1

(LOCATED IN CONDENSING FAN)

1P2

CF2 O.L.

2P22P1

1P1

ST1-NO

CC1-NO

COM NC

TS6

LPS1 HPS1

CF1 O.L.

21 24

R17

CF2

CF1

A1A1A2

CONDENSING FA N 2

CONDENSING FA N 1

COMPRESSOR INTERLOCKS

CC2

CC1

COMPRESSOR 2

COMPRESSOR 1

COMPRESSOR 2

CONDENSING FAN 1

CONDENSING FAN 2

CC1

CC2

CF1

CF2

CH1 CH2

DB1

o o

RETURN AIR SENSOR

620 OHM RESISTOR OR

OUTDOOR AIR

SENSOR

SO+

SR+ SO

COM

TR1

TS2

ECONOMIZER

ECONOMIZER CONTROL

A1 A2

ECONOMIZER INDICAT OR

7 C

THERMOSTA T(S) TS1, TS2, TS6

24 VA C

THERMOSTAT CONTROLLER(S)

OA-SENSOR

SENSOR

COM

R14

21 12

ROTATION SENSOR

R14

ROTATION SENSOR

BLUE

PINK

LT. BLUE

ORANGE

LT. BLUE

ORANGE

PURPLE

LT. BLUE

YELLOW

ORANGE

RED RED

REDRED

BROWN

RED RED

BROWN

BLACK BLACK BLACK

WHITE

YELLOW

5958

LPS2

HPS2

COMPRESSOR INTERLOCKS

R17

BLACK

A1 A2

CIRCUIT 1

CIRCUIT 2

FCS2

Following are several examples of typical wiring diagrams located in the unit control center. These wiring diagrams include a legend highlighting which accessories were provided with the unit. Factory wiring and ﬁeld wiring are also indicated.

The example below includes:

 • FactoryControlsforEconomizerOperation  • EnergyRecoveryWheelRotationSensor  • MotorizedOutdoorAirandExhaustAirIntakeDampers  • TimedExhaustFrostControl  • PackagedDXControlandSafetyCircuit

Many other factory installed and wired accessories are available.

VersiVent Energy Recovery Unit

Page 24

ENERGY WHEEL

ENERGY RECOVERY

FACTORY SUPPLIED AND WIRED

MULTI-VOLTAGE PRIMARY 24 SECONDARY

TR1

TO UNIT

MAIN POWER

DS1

SUPPLY DAMPER

LEGEND

C1 COOLING STAGE 1 RELAY C2 COOLING STAGE 2 RELAY CC COMPRESSOR CONTACTOR CF CONDENSING FAN CONTACTOR CH COMPRESSOR SUMP HEATER D DAMPER DB POWER DISTRIBUTION BLOCK DL DAMPER LIMIT SWITCH DS DISCONNECT SWITCH EC ECONOMIZER CONTROLLER FCS CONDENSOR FAN CYCLE SWITCH FU FUSES FU5 CONTROL TRANSFORMER FUSES (NOT ON CLASS II) FZ1 FREEZE PROTECTION HG HOT GAS REHEAT VALVE HPS HIGH PRESSURE SWITCH (MANUAL RESET) LPS LOW PRESSURE SWITCH PS1 WHEEL FROST PRESSURE SWITCH PS2 SUPPLY DIRTY FILTER PRESSURE SWITCH PS3 EXHAUST DIRTY FILTER PRESSURE SWITCH R1 ENERGY WHEEL RELAY/CONTACTOR R2 OCCUPIED/UNOCCUPIED RELAY R3 EXHAUST BLOWER VFD RELAY R4 SUPPLY BLOWER VFD RELAY R5 MODULATING WHEEL FROST CONTROL RELAY R6 ECONOMIZER RELAY R7 COMPRESSOR INTERLOCK RELAY R8 EVAP RELAY (INDIRECT) R9 EVAP RELAY (DIRECT) R10 UNIT RELAY R11 POST HEAT RELAY R12 ROOM CALL FOR COOL RELAY R13 ROOM CALL FOR HEAT RELAY R14 ROTATION SENSOR RELAY R15 ENERGY WHEEL RELAY R16 HOT GAS REHEAT RELAY S1 FAN SWITCH S2 ROTATION SENSOR (LOCATED BY WHEEL) S3 ROTATION SENSOR (LOCATED BY WHEEL) S4 CALL FOR HEAT SWITCH S5 OCC/UNOCC SWITCH - CLOSED=UNOCCUPIED/OPEN=OCCUPIED S6 CALL FOR COOL SWITCH (FIRST STAGE) S7 CALL FOR COOL SWITCH (SECOND STAGE) S8 CALL FOR DEHUMIDIFICATION SWITCH S9 ROOM RESET SWITCH ST MOTOR STARTER T1 FROST CONTROL TIMER TYPICAL SETTINGS t1(OFF) = 5 MIN., t2(ON) = 30 MIN. T2 ROTATION SENSOR TIMER T3 ROTATION SENSOR TIMER T4 ECONOMIZER WHEEL JOG TIMER TYPICAL SETTINGS t1(OFF) = 3 HRS., t2(ON) = 10 SEC. T5 EVAP DELAY OFF TIMER T6 COMPRESSOR MINIMUM OFF TIMER (TYP. 3 MIN.) T7 COMPRESSOR MINIMUM OFF TIMER (TYP. 3 MIN.) T8 COMPRESSOR MINIMUM ON TIMER (TYP. 5 MIN.) TR TRANSFORMER TS4 ROOM OVERRIDE SENSOR

o FIELD WIRED

FIELD CONTROL WIRING RESISTANCE SHOULD NOT EXCEED 0.75

OHM. IF RESISTANCE EXCEEDS 0.75 OHM THEN CONSULT FACTORY.

USE 14 GAUGE MINIMUM WIRE THICKNESS FOR CONTROL WIRING.

REPLACEMENT FUSES: MUST HAVE A MINIMUM I.R. RATING OF 5 KA

CAUTION:

UNIT SHALL BE GROUND IN ACCORDANCE WITH N.E.C. POWER MUST BE OFF WHILE SERVICING.

* *

EXHAUST DAMPER

GROUND

EXHAUST FAN

SUPPLY FAN

ST2

O.L.

MOTOR

ST1

O.L.

MOTOR(S)

TO L1 AND L3 ON

CR IN IG FURNACE

ST1 O.L.

95 96

ST2 O.L.

95 96

ST1

A2 A1

ST2

A2 A1

SUPPLY FAN

EXHAUST FAN

ST2

13 14

R14

ROTATION SENSOR

R11

TO "A" AND "RH"

IN IG FURNACE

POST HEAT

NO1

NO2

NO3

13 14

ST1

NO5

NO6

J13

J12

NO4

NO7

J14

VG0

IDC1

ID8

ID7

ID6

ID5

ID1

ID4

ID3

ID2

BC5

BC4

+VDC

DDC

CONTROLLER

NO8

NC8

J15

R14

21 12

USER INTERFACE

ALARM NO/NC CONTACTS

ALARM

NOC

PS2

PS1

NO C

ST1-AUX

NO C

TO NC ON T2

IN IG FURNACE

GND

TO NO ON T2

IN IG FURNACE

DDC SETUP CODE

X 0Y 1 1

R15

3 4

ENERGY WHEEL RELAY

OAI

ACC

OAD

R15

1 2R1A2 A1

ENERGY WHEEL

PINK

LT. BLUE

PINK

YELLOW

BROWN

ORANGE

PURPLE

BLUE

YELLOW

ORANGE

YELLOWBROWN

LT. BLUE

BROWN

PURPLE

ORANGE

RED

ORANGE

YELLOW

PINK

BLUE

WHITE

BROWN

RED

11 14

RED

BROWN

CC2

CC1

COMPRESSOR 1

COMPRESSOR 2

CONDENSING FAN 1

COMPRESSOR 2

COMPRESSOR 1

CONDENSING FAN 2

CC1

CC2

CF1

CF2

CH1 CH2

DB1

RED

CC2-NO

CC1-NO

HPS1LPS1

52 53

CONDENSING FAN 2

CONDENSING FAN 1

COMPRESSOR INTERLOCKS

CF2

CF1

* * *

* *

LPS2 HPS2

COMPRESSOR INTERLOCKS

A1 A2

21 24 2421

FCS2

FCS1

55 56

Wiring Diagram

The wiring diagram below includes a Factory Mounted DDC controller. The DDC controller operates the unit based on a built-in program. Additional features shown are:

 • EnergyRecoveryWheelRotationSensor • IGFurnacePowerandControlOutput  • PackagedDXControlandSafetyCircuit • TemperatureandPressureSensors

The DDC setup code can be cross-referenced with the DDC Controller IOM (Part #469690) for speciﬁc control information.

VersiVent Energy Recovery Unit

Page 25

Sequence of Operation

Basic Unit

The VER units are pre-wired such that when a call for outside air is made (via ﬁeld supplied 24 VAC control signal wired to unit control center), the supply fan, exhaust fan and energy wheel are energized and optional motorized dampers open. The VER units can be supplied with or without heating coils. Controls can be supplied by Greenheck or by the controls contractor. If supplied by the controls contractor, they would provide, mount, and wire any temperature controllers and temperature or relative humidity sensors required for the unit to discharge air at the desired conditions. However, temperature, pressure, and current sensors can be provided by Greenheck for purposes of monitoring via the Building Management System (see Optional Accessories section).

Summer Operation

Outdoor air is preconditioned (temperature and moisture levels are decreased) by the transfer of energy from the cooler, drier, exhaust air via the energy recovery wheel. Units supplied with cooling coils can further cool the air coming off the wheel and strip out moisture to levels at or below room design. A heating coil downstream of the cooling coil can reheat the air to a more comfortable discharge temperature to the space.

The VER model can be supplied with a wrap around heatpipe for additional precooling of the outdoor air prior to entering the cooling coil. The heatpipe also provides reheat after the cooling coil for applications where the outdoor needs to be provided at a space neutral condition.

Standard DX Sequence of Operation:

Unit without economizer

Ambient temperatures above 55ºF

• Firstcallforcool,theunitwillturnontherst

compressor.

• Onthesecondcallforcool,theunitwillturnon

the second compressor if available. (seven (7) or larger tonnage system).

Ambient temperatures below 55ºF

• DXsystemlockedoutandwillnotoperate.

Unit with economizer

With economizer conditions available and ambient temperature above 55ºF

• Firstcallforcool-theunitwillcheckifitcan

use economizer air. If it can, the wheel will shut off or modulate and the cooling coil will be deenergized.

• Secondcallforcool-theunitwillturnona

compressor to provide the space with further cooling.

With economizer conditions available and ambient temperature below 55ºF

• Firstcallforcool-theunitwillengageeconomizer

allowing free cooling down to minimum set point, factory set at 50ºF.

• Secondcallforcool-theDXsystemislockedout,

not allowing compressors to run below 55ºF. First stage of cooling will still operate unless ambient temperature drops below economizer set point.

Without economizer conditions available and ambient temperature above 55ºF

• Firstcallforcool-theunitwillturnoncompressor

one.

• Secondcallforcool-theunitwillturnonthe

second compressor if available. (10 or larger tonnage system).

Economizer Operation: Refer to Economizer Application/Operation section.

Winter Operation

Outdoor air is preconditioned (temperature and moisture levels are increased) by the transfer of energy from the warmer, more humid exhaust air via the energy recovery wheel. Units supplied with heating coils can further heat the air coming off the wheel to levels at or above room design.

Frost Control Operation: Refer to Frost Control Application/Operation section.

Rotation Sensor: Refer to Optional Accessories section

Dirty Filter Sensor: Refer to Optional Accessories section

CO2 Sensor: Refer to Optional Accessories section

DX Safety and General Control Sequence: To

prevent damage to the system, there is a safety loop incorporated into the controls. This loop includes a check to make sure the supply fan starter is pulled in, ambient temperature is above 55ºF, and the lowand high-pressure switches are not tripped out. After this loop is veriﬁed, a relay then pulls in to start the anti-cycle timer. (Typical setting is 3 minutes). Once the timer has counted down, only then can the compressor contact pull in. Once the compressor contact pulls in, the ﬁrst stage of condensing fans turns on. If pressure in the condensing coil increases to a point at which more heat needs to be removed from the system, the fan cycle switch will close and the second stage of condensing fans turns on.

VersiVent Energy Recovery Unit

Page 26

Start-Up

DANGER

Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit to OFF at disconnect switch(es). Unit may have multiple power supplies.

WARNING

Use caution when removing access panels or other unit components, especially while standing on a ladder or other potentially unsteady base. Access panels and unit components can be heavy and serious injury may occur.

Do not operate energy recovery ventilator without the filters and birdscreens installed. They prevent the entry of foreign objects such as leaves, birds, etc.

CAUTION

Do not run unit during construction phase. Damage to internal components may result and void warranty.

General factory information:

• Unitwasfactorytested.Allblowers,fans,

and compressors are set-up to run correct when supplied power. If any one fan is running backwards or the compressor is making loud noises, immediately turn off the power. Switch two leads on the incoming power to the disconnect. This will ensure proper operation of the unit. Failure to comply may damage the compressors and void the warranty.

• Donotjumperanysafetydeviceswhenoperating

the unit. This may damage components within or cause serious injury or death.

• Donotoperatecompressorwhentheoutdoor

temperature is below 40ºF.

• Donotshort-cyclethecompressor.Allow

5 minutes between “on” cycles to prevent compressor damage.

• Priortostartinguptheunit,powermustbe

energized for 24 hours without a call for cool to allow the compressor crankcase heaters time to boil off any liquid refrigerant present in the compressor.

• DXsystemischargedwithrefrigerant.Start-up

must be performed by EPA Certiﬁed Technician.

General Start-Up Information

Every installation requires a comprehensive startup to ensure proper operation of the unit. As part of that process, the following checklist must be completed and information recorded. Starting up the unit in accordance with this checklist will not only ensure proper operation, but will also provide valuable information to personnel performing future maintenance. Should an issue arise which requires factory assistance, this completed document will allow unit experts to provide quicker resolve. Qualiﬁed personnel should perform start-up to ensure safe and proper practices are followed.

Unit Model Number _______________________________

(e.g. VER-65)

Unit Serial Number _______________________________

(e.g. 04C99999 or 10111000)

Energy Wheel Date Code __________________________

(e.g. 0450)

Compressor 1 Model Number ______________________

(e.g. ZR36-XXXXX)

Compressor 2 Model Number ______________________

(e.g. ZR36-XXXXX)

Start-Up Date _______________________________

Start-Up Personnel Name __________________________

Start-Up Company _______________________________

Phone Number _______________________________

Pre Start-Up Checklist – check as items are

completed.

o Disconnect and lock-out all power switches

o Remove any foreign objects that are located in the

energy recovery unit.

o Check all fasteners, set-screws, and locking collars

on the fans, bearings, drives, motor bases and accessories for tightness.

o Rotate the fan wheels and energy recovery wheels

by hand and ensure no parts are rubbing. If rubbing occurs, refer to Start-Up section for more information.

o Check the fan belt drives for proper alignment

and tension (refer to Start-Up section for more information).

o Filters can load up with dirt during building

construction. Replace any dirty pleated ﬁlters and clean the aluminum mesh ﬁlters in the intake hood (refer to Routine Maintenance section).

o Verify that non-motorized dampers open and close

properly.

o Check the tightness of all factory wiring

connections.

o Verify control wire gauge (refer to the Electrical

Connections section).

o Verify diameter seal settings on the energy

recovery wheel (refer to Start-Up section for more information).

VersiVent Energy Recovery Unit

Page 27

oVerify proper drain trap installation (refer to Drain

Trap section).

oLook over the piping system. Inspect for oil at

all tubing connections. Oil typically highlights a leak in the system. If a leak is present, refer to the Maintenance section in this manual.

oInspect all coils within the unit. Fins may get

damaged in transit or during construction. Carefully straighten fins with a fin comb.

oIf there is an indirect gas-fired furnace in this unit,

refer to the PVF IOM provided with this unit for Pre Start-Up information.

For plenum or backward inclined fans, check the radial gap and overlap. Adjust if necessary.

Additional Information for Units with Packaged DX

oCheck condensing fans for any damage or

misalignment. Spin the blades and make sure they don’t contact any parts and are free turning without any resistance.

o This unit contains a crankcase heater for each

compressor which needs power supplied to it 24 hours prior to start-up. If start-up is scheduled in 24 hours, unlock the disconnect power and energize unit.

SPECIAL TOOLS REQUIRED

• VoltageMeter(withwireprobes)

• AmperageMeter

• PressureGauges–R410aRefrigerant

• TemperatureGaugescapableofmeasuringpipe

temperature

• Thermometer

• Inclinemanometerorequivalent

Start-Up Checklist

The unit will be in operational mode during start-up. Use necessary precautions to avoid injury. All data must be collected while the unit is running. In order to measure volts & amps, the control center door must be open, and the unit energized using a crescent wrench to turn the disconnect handle.

Start-Up Procedure

 • MakesurePreStart-Upchecklistiscomplete.  • JumperRtoG,RtoY1,andRtoY2onthe

control board.

 • Turnthedisconnecton.Ifyourunitcontains

compressors (optional), after 3 minutes they will energize. Make sure all fans and compressors are rotating in the correct direction.

WARNING

All motor(s) / compressor(s) have been checked for rotation. If blower rotation is incorrect, wiring must be changed at the disconnect to ensure all motor(s) / compressors are corrected.

Operation of scroll compressor(s) in this unit are directional and will be damaged if run with the wrong direction.

 • IfyourunitcontainsaPackagedDXsystem

(optional), allow the unit to run until the refrigerant system stabilizes. Approximately 1-2 minutes.

 • Takethefollowingmeasurementswhiletheunitis

running to ensure proper operation.

Additional Information for Units with Packaged DX

 • Turnthedisconnecton.After3minutes

compressors will come on. Make sure all fans and compressors are rotating the correct direction.

 • Allowtheunittorununtiltherefrigerantsystem

stabilizes. Approximately 1-2 minutes.

Start-Up Checklist

Check line voltage at unit disconnect _______ L1-L2 volts _______ L2-L3 volts _______ L1-L3 volts

Motor Amp Draw

  •SupplyFan •ExhaustFan

_______ L1 amps ______ L1 amps _______ L2 amps ______ L2 amps _______ L3 amps ______ L3 amps

Fan RPM _______ Supply Fan ______ Exhaust Fan

Correct fan rotation direction Supply Fan Yes / No Exhaust Fan Yes / No

Energy Wheel Motor _______ L1 amps _______ L2 amps _______ L3 amps

Electric Post-Heater Voltage _______ L1-L2 volts _______ L2-L3 volts _______ L1-L3 volts

VersiVent Energy Recovery Unit

Page 28

Start-Up Checklist (Units with Packaged DX)

Outdoor Air Temperature ________Deg. F.

Return Air Temperature ________Deg. F.

Outdoor Air Relative Temperature _________% RH

Return Air Relative Temperature _________% RH

CIRCUIT A

oCompressor: _______ L1 amps _______ L2 amps _______ L3 amps

_______ Crankcase Heater

Superheat _______Deg. F.

Should be between 8º and 12ºF.

Subcooling _______Deg. F.

Should be between 12º and 17ºF.

Discharge Pressure ________% RH

Should be between 300 and 500 PSIG

Suction Line Pressure ________ % RH

Should be between 100 and 135 PSIG

Liquid Line Temperature _______ Deg. F.

Suction Line Temperature _______ Deg. F.

Moisture Indicating Sight Glass Liquid Visible Yes / No Color of Center Dot Green / Yellow

Oil in Compressor Sight Glass Yes / No

Hot Gas Bypass Operational Yes / No

oCondensing Fan 1: _______ L1 amps _______ L2 amps _______ L3 amps

oCondensing Fan 2: _______ L1 amps _______ L2 amps _______ L3 amps.

CIRCUIT B

oCompressor: _______ L1 amps _______ L2 amps _______ L3 amps

_______ Crankcase Heater

Superheat _______Deg. F.

Should be between 8º and 12ºF.

Subcooling _______Deg. F.

Should be between 12º and 17ºF.

Discharge Pressure ________% RH

Should be between 300 and 500 PSIG

Suction Line Pressure ________ % RH

Should be between 100 and 135 PSIG

Liquid Line Temperature _______ Deg. F.

Suction Line Temperature _______ Deg. F.

Moisture Indicating Sight Glass Liquid Visible Yes / No Color of Center Dot Green / Yellow

Oil in Compressor Sight Glass Yes / No

Packaged DX units are provided fully charged with R410a refrigerant

VersiVent Energy Recovery Unit

Page 29

Optional Accessories Checklist

Refer to the respective sections in this Installation, Operation and Maintenance Manual for detailed information.

Refer to wiring diagram in unit control center to determine what electrical accessories were provided.

Provided with Unit? Frost Control Application / Operation section: Setting Factory Default

Yes No Frost Control set point 5ºF

Differential 2ºF Timer Refer to IOM

Yes No Frost Control Modulating Refer to IOM

Economizer Application / Operation section:

Yes No Economizer (temperature)

Set point 65ºF

Offset 20ºF

Differential 2ºF

Yes No Economizer (enthalpy)

Set point D

Yes No Economizer (modulating) Refer to IOM

Optional Accessories section: Operational

Yes No Wheel Rotation Sensor Yes No N/A

Yes No OA Dirty Filter Sensor Yes No N/A

Yes No EA Dirty Filter Sensor Yes No N/A

Yes No CO2 Sensor Yes No N/A

Yes No Service Outlet Yes No N/A

Yes No Vapor Tight Lights Yes No N/A

Yes No Remote Control Panel Yes No N/A

Variable Frequency Drives section: Operational

Yes No Blower VFDs Yes No N/A

Yes No Wheel VFD Yes No N/A

Damper section: Operational

Yes No Outdoor Air Damper Yes No N/A

Yes No Exhaust Air Damper Yes No N/A

Yes No Night Setback Damper Yes No N/A

Yes No Indirect Gas Furnace (refer to the PVF IOM, Part #461006 for start-up information)

VersiVent Energy Recovery Unit

Page 30

Unit Start-Up

Belt Span

Deﬂection =

Belt Span

WRONG WRONG

WRONG CORRECT

WRONG WRONG

WRONG CORRECT

MOTOR

FA N

MOTOR

Overlap

Radial

Gap

Refer to Component section for component locations.

Fans

The VER models contain a plenum supply fan and a forward curved exhaust fan. The fans should be checked for free rotation. If any binding occurs, check for concealed damage and foreign objects in the fan housing. Be sure to check the belt drives per the startup recommendations in the following section.

When operating conditions of the fan are to be changed (speed, pressure, temperature, etc.), consult Greenheck to determine if the unit can operate safely at the new conditions.

Supply Fan (Plenum Type)

The model VER contains one plenum supply fan located on the end of the unit opposite the outdoor air intake (see beginning of Unit Start-Up section for diagram of unit layout). Efﬁcient fan performance can be maintained by having the correct radial gap and overlap. These items should be checked before startup and after the fan has been in operation for 24 hours.

Radial Gap: Radial gap is adjusted by loosening the inlet cone/ring on the wheel. If additional adjustment is required to maintain a constant radial gap, loosening the bearing bolts and centering the wheel is acceptable as a secondary option.

Overlap: Proper overlap is obtained by loosening the wheel hub from the shaft and adjusting the wheel to maintain an “A” dimension.

Refer to Part #463687 Centrifugal Fan IOM for additional start-up and maintenance information regarding the QEP Plenum Supply Fan.

Exhaust Fans (Forward Curved Type)

The model VER contains one forward curved exhaust fan located on either side of the unit (see Basic Unit Operation). The forward curved fan should be checked for free rotation. If any binding occurs, check for concealed damage and foreign objects in the fan

VersiVent Energy Recovery Unit

Supply Fan

CAUTION

Plenum

Forward Curved

Radial Gap

and Overlap

“A” Dimension

Model

VER-45

VER-65

VER-90

Supply

Fan

QEP-15 5 ±1/8

QEP-18 6 3/8 ±1/8

QEP-20 7 ±3/16

QEP-24 8 5/8 ±1/4

Exhaust Fan

A Dimension

± Tolerance

(inches)

housing. Be sure to check the belt drives per the Belt Drive Installation section (Unit Start-Up) and per the Fan Belts section (Routine Maintenance).

Fan Performance Modiﬁcations

Due to job speciﬁcation revisions, it may be necessary to adjust or change the sheave or pulley to obtain the desired airﬂow at the time of installation. Start-up technician must check blower amperage to ensure that the amperage listed on the motor nameplate is not exceeded. Amperage to be tested with access doors closed and ductwork installed.

Fan Belt Drives

The fan belt drive components, when supplied by Greenheck, have been carefully selected for the unit’s speciﬁc operating condition. Utilizing different components than those supplied could result in unsafe operating conditions which may cause personal injury or failure of the following components:

 •FanShaft • Bearings •Motor  •FanWheel • Belt

Tighten all fasteners and set screws securely and realign drive pulleys after adjustment. Check pulleys and belts for proper alignment to avoid unnecessary belt wear, noise, vibration and power loss. Motor and drive shafts must be parallel and pulleys in line (see diagrams in this section).

Belt Drive Installation

1. Remove the protective coating from the end of the fan shaft and assure that it is free of nicks and burrs.

2. Check fan and motor shafts for parallel and angular alignment.

3. Slide sheaves on shafts. Do not drive sheaves on as this may result in bearing damage.

4. Align fan and motor sheaves with a straight-edge or string and tighten.

5. Place belts over sheaves. Do not pry or force belts, as this could result in damage to the cords in the belts.

6. With the fan off, adjust the belt tension by moving the motor base. (See belt tensioning procedures in the Routine Maintenance section of this manual). When in operation, the tight side of the belts should be in a straight line from sheave to sheave with a slight bow on the slack side.

Page 31

Direction of Fan Wheel Rotation

Backward Inclined

Airﬂow

Backward Inclined

Forward Curved

Blower access is labeled on unit. Check for proper wheel rotation by momentarily energizing the fan. Rotation is determined by viewing the wheel from the drive side and should match the rotation decal afﬁxed to the fan housing (see Rotation Direction ﬁgures). If the wheel is rotating the wrong way, direction can be reversed by interchanging any two of the three electrical leads. Check for unusual noise, vibration, or

overheating of bearings. Refer to the Troubleshooting section of this manual if a problem develops.

Fan RPM

Supply fan and exhaust fan will have an adjustable motor pulley (on 15 HP and below) preset at the factory to the customer speciﬁed RPM. Fan speed can be increased or decreased by adjusting the pitch diameter of the motor pulley. Multi-groove variable pitch pulleys must be adjusted an equal number of turns open or closed. Any increase in fan speed represents a substantial increase in load on the motor. Always check the motor amperage reading and compare it to the amperage rating shown on the motor nameplate when changing fan RPM. All access doors must be installed except the control center door. Do not operate units with access doors open or

without proper ductwork in place as the fan motors will overload.

Vibration

Excessive vibration may be experienced during initial start-up. Left unchecked, excessive vibration can cause a multitude of problems, including structural and/or component failure. The most common sources of vibration are listed.

Many of these conditions can be discovered by careful

Wheel Unbalance Drive Pulley Misalignment Incorrect Belt Tension Bearing Misalignment Mechanical Looseness Faulty Belts Drive Component Unbalance Poor Inlet/Outlet Conditions Foundation Stiffness

consulted. If the problem is wheel unbalance, in-place balancing can be done.

Generally, fan vibration and noise is transmitted to other parts of the building by the ductwork. To eliminate this undesirable effect, the use of heavy canvas connectors is recommended.

observation. Refer to the Troubleshooting section of this manual for corrective actions. If observation cannot locate the source of vibration, a qualiﬁed technician using vibration analysis equipment should be

Spring Vibration Isolators

Two to four securing bolts prevent unwanted fan and isolator movement during shipping. Proper unit operation requires the removal of these bolts.

Remove the 5/16 in. hex head bolts from each corner of the fan sub-frame.

Coils

Leak test thermal system to insure tight connections. Check for properly trapped condensate drain.

Energy Recovery Wheel

The VER models contain a total energy recovery wheel. The wheels are inspected for proper mechanical operation at the factory. However, during shipping and handling, shifting can occur that may affect wheel operation. The wheel is accessible through the access door marked “Energy Wheel Cassette Access”. To access seals in VER units, pull the cassettes out following the instructions in the Energy Recovery Wheel Maintenance section.

Turn the energy recovery

Adjustable Air Seals

Bearing Support

wheels by hand to verify free operation. The wheel should rotate smoothly and should not wobble.

Drive Belt

Drive Pulley

Label showing cassette serial # and date code

Drive Belt

Inspect the drive belt. Make sure the belt rides smoothly through the pulley and over the wheel rim.

Air Seals

Check that the air seals located around the outside of the wheel and across the center (both sides of wheel) are secure and in good condition. Air seal clearance is determined by placing a sheet of paper, to act as a feeler gauge, against the wheel face. To access seals in VER units, pull the cassettes out following the instructions in the Energy Recovery Wheel Maintenance section. To adjust the air seals, loosen all eight seal retaining screws. These screws are located on the bearing support that spans the length of the cassette through the wheel center. Tighten the screws so the air seals tug slightly on the sheet of paper.

Replace cassette into unit, plug in wheel drive, replace access door and apply power. Observe by opening door slightly (remove ﬁlters if necessary to view wheel). The wheel should rotate freely at about 50-60 rpm.

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Page 32

Factory Installed Refrigeration System Components for Units with Packaged DX (optional)

TYPICAL REFRIGERATION CIRCUIT

(HOT GAS BYPASS SHALL BE PROVIDED ON CIRCUIT A)

CHARGING

PORT

EQUALIZER

LINE

CONDENSER COIL

COMPRESSOR(S)

HOT GAS BYPASS VALVE

(HGBV)

DISCHARGE

SUCTION GAS

LIQUID

HEAD PRESSURE

FAN CONTROL

(LOW AMBIENT)

HIGH PRESSURE

600 / 420 PSI

OPEN / RESET SWITCH

LOW PRESSURE

50 / 90 PSI

OPEN / RESET SWITCH

HIGH PRESSURE

ACCESS PORT

LOW PRESSURE

ACCESS PORT

TXV

SIGHT GLASS

LIQUID LINE FILTER DRIER

SOLENOID VALV E

SCHRAEDER VALV EMANUAL VALV E THERMAL EXPANSION VALVE (TXV)

HOT GAS BYPASS VALVE (HGPB)

1. Thermostatic Expansion Valve (TXV) - each unit is equipped with a thermal expansion valve. The valve controls the ﬂow of liquid refrigerant entering the evaporator coil by maintaining a constant, factory set superheat of 10ºF. The valve is located on the side of the evaporator coil and can be accessed through the exhaust airstream, through the coil panel access door.

2. Refrigerant Distributor - attached to the TXV is a refrigerant distributor. The refrigerant distributor evenly distributes the refrigerant to each circuit of the evaporator coil to provide optimum performance.

3. Evaporator Coil - each unit contains a multiple circuit evaporator coil. The coil is located in the outdoor airstream, directly after the energy wheel. In the DX system, the liquid refrigerant is expanded in the TXV, and then ﬂows through the evaporator coil. The refrigerant enters the coil as low temp liquid/gas where it eventually boils into a low temp, low pressure gas prior to going to the compressor. To ensure proper operation, the coil surface must be cleaned so that air movement over the coil provides the necessary heat transfer.

4. Low Limit Pressure Switch - the unit includes a low limit pressure switch (located in the compressor compartment). The switch is installed

VersiVent Energy Recovery Unit

in the suction line and shuts off the DX system when the suction pressure drops to 50 psi for R410a. The switch has a built in auto-reset, which will close the circuit and allow the system to run when the pressure increases back to 90 psi for R410a.

5. Compressors - each unit includes 1, 2 or more efﬁciency scroll type compressors depending on needed capacity. Scroll type compressors are essentially maintenance free since they are a self-contained, self-cooling design. The scroll compresses the refrigerant in the gaseous state to a high temperature, high pressure gas.

Compressor protective devices:

Thermal Overload - each compressor is equipped

with an auto reset thermal overload

High Temp Protection - internal devices within

the compressor protect it against excessively high discharge gas temperatures

Crankcase Heater - Liquid refrigerant is

incompressible. Therefore, a crankcase heater is installed around each compressor in the unit to boil any liquid refrigerant that may be absorbed into the oil during idle periods. System power energizes the heater; it is recommended the heater is allowed to run 24 hours prior to compressors being started.

Page 33

6. Condensing Coil - each unit contains a multiple circuit condensing coil mounted on the exterior of the unit. High temperature, high pressure gas from the compressor enters the coil and is eventually cooled into a high temperature, high pressure liquid. The condensing fans move air over the coil which pulls the heat out of the refrigerant. To ensure proper operation, the coil must be cleaned so that air movement over the coil provides the necessary heat transfer.

7. Condenser Fans - the unit is equipped with two direct-drive condensing fans. The fans provide the necessary airﬂow to cool the refrigerant in the condensing coil. Depending on head pressure, one fan may not be running, which is normal operation for this unit and does not highlight a problem. The motors are equipped with sling protection to guard against water penetration, and are thermally protected. The thermal overloads shut down the condensing fans.

8. High Limit Pressure Switch - to safely shutdown the DX system, in case of an increase in refrigerant pressure, a high limit pressure switch is included (located in compressor compartment). The switch is located in the compressor compartment. It trips when refrigerant pressure increase to 600 psi for R410a in the liquid line, and can only be manually reset when the pressure drops below 420 psi. Typically if the high limit switch trips, a failure in the system has occurred and more investigation is needed to determine the underlying problem.

9. Head Pressure Cycle Switch - to maintain proper refrigerant pressures, a Fan-Cycle switch that operates on head pressure is installed in the liquid line. When liquid line refrigerant pressure increases to 400 psi for R410a, the switch closes and turns on an additional condensing fan to aid in cooling the refrigerant. After turning on, the fan will run until liquid line pressure drops down to 300 psi for R410a where it cycles off. The switch is located in the compressor compartment.

10. Liquid Line Filter Drier - the liquid line ﬁlter drier prevents moisture and foreign matter from entering the thermal expansion valve. It is mounted in the compressor compartment.

11. Moisture Indicating Sight Glass - moisture in a DX system can cause great harm and break down the refrigerant. Located in the compressor compartment is a moisture indicating sight glass. During normal operating conditions, the sight glass should typically be liquid. Some gas is acceptable, but excessive bubbles may indicate improper charge or a leak in the system. A green dot means moisture is below a safe operation level in the refrigerant, while a yellow dot indicates moisture has been introduced into the system and needs to be addressed.

12. Hot Gas Bypass Valve - on units equipped with hot bypass, hot gas from the compressor

is injected into the liquid line of the evaporator coil after the TXV. This process starts to occur when suction gas temperatures drop below 28ºF, which is 32º–34ºF coil surface temperature. Hot gas helps prevent the evaporator coil from freezing up and the compressor from cycling. The valve is factory set, but can be adjusted to exact speciﬁcations once installed in the ﬁeld.

13. Access Ports - for easy measurement and charging access, several ports are provided throughout the system. These can be used to measure system pressures and also charge or evacuate the system. Most ports are located in the compressor compartment for easy access.

Valve Adjustment To adjust the valve, connect a pressure gauge to

the suction line and block the entering air to the evaporator coil. The Valve should begin to open when the suction pressure drops to approximately 115 PSIG for R410a (the valve will feel warm to the touch). Adjustments are made by ﬁrst removing the cap on the valve and then turning the adjusting stem clockwise to increase the setting pressure and counterclockwise to decrease the setting pressure. Allow several minutes between adjustments for system to stabilize. When adjustment is complete, replace the cap on the valve.

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Page 34

Routine Maintenance

DANGER

CAUTION

This unit requires minimal maintenance to operate properly. To ensure proper operation and longevity, the following items should be completed. The items in this list assume a relatively clean air environment, and may require attention more frequently in a dirty or dusty area. If this unit contains an Indirect Gas Heater, refer to the Installation, Operation and Maintenance Manual provided with the unit for maintenance purposes. A Certiﬁed Technician should complete all refrigerant systems checks.

Maintenance Frequency:

Monthly

1. External Filter Check for cleanliness – clean if required

2. Internal Filter Check for cleanliness – replace if required

3. Condensate Drain (if applicable) Inspect and clean – reﬁll with water

4. Bearings Lubricate per the schedule in the Fan Bearings section

Semi-Annually

1. Fan Belts Check for wear, tension, alignment

2. Energy Recovery Wheel Check for cleanliness – clean if required

3. Check for belt wear Check pulley, bearings, and motor

4. Bearings Lubricate per the schedule in the Fan Bearings section

Annually

It is recommended that the annual inspection and maintenance occur at the start of the cooling season. After completing the checklist, follow the unit startup checklist provided in the manual to ensure the refrigeration system operates in the intended matter.

1. Lubrication Apply lubrication where required

2. Dampers Check for unobstructed operation

3. Motors Check for cleanliness

4. Fan Belts Check for wear, tension, alignment

5. Motors Check for cleanliness

6. Blower Wheel & Fasteners Check for cleanliness Check all fasteners for tightness Check for fatigue, corrosion, wear

7. Bearings Lubricate per the schedule in the Fan Bearings section

8. Energy Recovery Wheel Check for cleanliness – clean if required Check belt for wear Check pulley, bearings, and motor

9. Door Seal Check if intact and pliable

10. Wiring Connections Check all connections for tightness

Units with Packaged DX

1. Evaporator Coil Maintenance Check for cleanliness – clean if required

2. Condenser Coil Maintenance Check for cleanliness – clean if required

3. Condensate Drain Inspect and clean – reﬁll with water

4. Condensing Fan Blades and Motor Check for cleanliness Check all fasteners for tightness Check for fatigues, corrosion, and wear

Maintenance Procedures:

Lubrication

Check all moving components for proper lubrication. Apply lubrication where required. Any components showing excessive wear should be replaced to maintain the integrity of the unit and ensure proper operation.

Dampers

Check all dampers to ensure they open and close properly and without binding. Backdraft dampers can be checked by hand to determine if blades open and close freely. Apply power to motorized dampers to ensure the actuator opens and closes the damper as designed.

Fan Belts

Belts must be checked on a regular basis for wear, tension, alignment, and dirt accumulation. Premature or frequent belt failures can be caused by improper belt tension (either too loose or too tight) or misaligned sheaves. Abnormally high belt tension or drive misalignment will cause excessive bearing loads and may result in failure of the fan and/or motor bearings. Conversely, loose belts will cause squealing on start-up, excessive belt ﬂutter, slippage, and overheated sheaves. Both loose and tight belts can cause fan vibration.

VersiVent Energy Recovery Unit

Page 35

Belt Span

Deflection =

Belt Span

When replacing belts on multiple groove drives, all belts should be changed to provide uniform drive loading. Do not pry belts on or off the sheave. Loosen belt tension until belts can be removed by simply lifting the belts off the sheaves. After replacing belts, insure that slack in each belt is on the same side of the drive. Belt dressing should never be used.

Do not install new belts on worn sheaves. If the sheaves have grooves worn in them, they must be replaced before new belts are installed.

The proper belt setting is the lowest tension at which the belts will not slip under peak load operation. For initial tensioning, set the belt deﬂection at 1/64-inch for each inch of belt span (measured half-way between sheave centers). For example, if the belt span is 64 inches, the belt deﬂection should be 1 inch (using moderate thumb pressure at mid-point of the drive). Check belt tension two times during the ﬁrst 24 hours of operation and periodically thereafter.

Fan Motors

Motor maintenance is generally limited to cleaning and lubrication. Cleaning should be limited to exterior surfaces only. Removing dust and grease buildup on the motor housing assists proper motor cooling. Never wash-down motor with high pressure spray. Greasing of motors is only intended when ﬁttings are provided. Many fractional motors are permanently lubricated for life and require no further lubrication.

Fan Wheel and Fasteners

Wheels require very little attention when moving clean air. Occasionally oil and dust may accumulate on the wheel causing imbalance. When this occurs the wheel and housing should be cleaned to assure smooth and safe operation. Inspect fan impeller and housing for fatigue, corrosion or wear.

Routinely check all fasteners, set screws and locking collars on the fan, bearings, drive, motor base and accessories for tightness. A proper maintenance program will help preserve the performance and reliability designed into the fan.

Fan Bearings

Most bearings are permanently lubricated and require no further lubrication under normal use. Normal use being considered -20ºF to 120ºF and in a relatively clean environment. Some bearings are re-lubricatable and will need to be re-greased depending on fan use. Check your bearings for grease zerk ﬁttings to ﬁnd out what type of bearing you have. If your fan is not being operated under normal use, bearings should be checked monthly for lubrication. Shaft bearings are the most critical moving part of a fan. Therefore, special attention should be given to keeping the bearings clean and well lubricated. Proper lubrication provides for reduction in friction and wear, transmission and dissipation of heat, extended bearing life and prevention of rust.

In order for a lubricant to fulﬁll these tasks, the proper grease applied at regular intervals is required. Refer to the recommended bearing lubrication schedule:

Bearing Lubrication Schedule

for Plenum Fans on VER Models

(Relubrication Schedule in Months)

Fan

RPM

To 250 6 6 6 6

500 6 6 6 5

750 6 5 4 3 1000 6 4 3 2 1250 5 3 2 1 1500 5 2 1 1 2000 5 1 1 .5 2500 4 .5 .5 .25 3000 4 .5 .25 .25 4000 3 .25 .25 .25 5000 2 .25 .25 .25

⁄2 to 1 11⁄8 to 11⁄2 15⁄8 to 17⁄8 115⁄16 to 23⁄16

If unusual conditions exist—temperatures below 32ºF or above 200ºF, moisture or contaminants—more frequent lubrication is required.

With the unit running, add grease very slowly with a manual grease gun until a slight bead of grease forms at the seal.

Be careful not to unseat the seal by over lubricating or using excessive pressure. A guide to the amount of grease to be used is to ﬁll 30% to 60% of available space in the bearing and housing.

A high quality lithium based grease conforming to NLGI Grade 2 consistency, such as those listed below should be used:

Mobil 532 Texaco Premium #2 B Shell Alvania #2 Mobilux #2 Texaco Multifak #2 Unirex 2

In addition to lubricating the bearings at speciﬁed intervals, set screws in the bearing collars should be checked for tightness. A bearing collar which has loosened will cause premature failure of the fan shaft. Fasteners attaching the bearings to the drive frame should also be checked. See bearing lubrication schedule.

Shaft Diameter in Inches

VersiVent Energy Recovery Unit

Page 36

Internal Filter Maintenance

The VER units will typically be provided with 2-inch, pleated ﬁlters in the supply air and exhaust airstream. These ﬁlters should be checked per a routine maintenance schedule and replaced as necessary to ensure proper airﬂow through the unit. See table below for pleated ﬁlter size and quantity for each unit. Replacement ﬁlters shall be of same performance and quality as factory installed ﬁlters. Filter type must be pleated design with integral metal grid. Two acceptable ﬁlter replacements are Aerostat Series 400 or Farr 30/30®.

Located downstream of the energy wheel in the VER, is an optional ﬁnal ﬁlter section. Either MERV 8, 11 or 13 ﬁlters are available in 2 or 4-inch depth. An acceptable replacement ﬁlter is an AmAir® 1100 or similar model.

Filter Size and Quantities

Model

VER-45 (4) 16x25x2 (4) 16x25x2 (4) 16x25x2 (4) 16x25x4

VER-65 (6) 16x25x2 (6) 16x25x2 (6) 16x25x2 (6) 16x25x4

VER-90 (6) 20x25x2 (6) 20x25x2 (8) 20x20x2 (8) 20x20x4

Wheel

Supply

Wheel

Exhaust

Final 2 inch

(optional)

Final 4 inch

(optional)

Outdoor Air Filters: Access to the outdoor air ﬁlters

is through the door labeled as “Filter Access” on the access side of the unit.

Exhaust Air Filters: Access to the exhaust air ﬁlters is through the door labeled as “Filter Access” on the access side of the unit.

Refer to Access Door Descriptions section for additional information on ﬁlter locations.

WARNING

REFER TO GENERAL SAFETY INFORMATION

Do not operate energy recovery ventilator without the filters and birdscreens installed. They prevent the entry of foreign objects such as leaves, birds, etc.

Do not remove access panels or other unit components while standing on a ladder or other unsteady base. Access panels and unit components are heavy and serious injury may occur.

External Filter Maintenance

Aluminum mesh, 2-inch deep ﬁlters are located in the supply weatherhood (if the weatherhood option was purchased). Filters should be checked and cleaned on a regular basis for best efﬁciency. The frequency of cleaning depends upon the cleanliness of the incoming air. These ﬁlters should be cleaned prior to start-up.

To access these ﬁlters, remove bottom bolt in the access door on the side of the weatherhood. Slide the access door up and then pull bottom out to remove door. Then, slide the ﬁlters out.

Outdoor air

intake hood

mesh ﬁlter

access

Clean ﬁlters by rinsing with a mild detergent in warm water.

Filters upstream of the coil should be checked regularly. If the ﬁlters are dirty, they should be cleaned or replaced. It is important that the coils stay clean to maintain desired airﬂow. See Filter Maintenance section for additional information.

Coil Maintenance

Units with Optional Heating or Cooling

Coils must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and if dirty, brush or vacuum clean. Soiled ﬁns reduce the capacity of the coil, demand more energy from the fan, and create an environment for odor and bacteria to grow and spread through the conditioned zone. High pressure water (700 psi or less) may be used to clean coils with ﬁn thickness over 0.0095 inches thick. TEST THE SPRAY PRESSURE over a small corner of the coil to determine if the ﬁns will withstand the spray pressure.

For coils with fragile ﬁns or high ﬁn density, foaming chemical sprays and washes are available. Many coil cleaners contain harsh chemicals, so they must be used with caution by qualiﬁed personnel only. Care must be taken not to damage the coils, including the ﬁns, while cleaning. Caution: Fin edges are sharp.

WARNING

Biological hazard. May cause disease. Cleaning should be performed by qualified personnel.

Drain pans in any air conditioning unit will have some moisture in them, therefore, algae and other organisms will grow due to airborne spores and bacteria. Periodic cleaning is necessary to prevent this buildup from plugging the drain and causing the drain pan to overﬂow. Inspect twice a year to avoid the possibility of overﬂow. Also, drain pans should be kept clean to prevent the spread of disease. Cleaning should be performed by qualiﬁed personnel.

Winterizing Coils

Coil freeze-up can be caused by such things as air stratiﬁcation and failure of outdoor air dampers and/ or preheat coils. Routine draining of water cooling coils for winter shutdown cannot be depended upon as insurance against freeze-up. Severe coil damage may result. It is recommended that all coils be drained as thoroughly as possible and then treated in the following manner.

Fill each coil independently with an antifreeze solution using a small circulating pump and again thoroughly drain. Check freezing point of antifreeze before proceeding to next coil. Due to a small amount of water always remaining in each coil, there will be a diluting effect. The small amount of antifreeze solution remaining in the coil must always be concentrated enough to prevent freeze-up.

VersiVent Energy Recovery Unit

Page 37

Bracket Segment Retainer

Lift away from segment

Catch Segment Retainer

Push toward center

Center of Wheel

Spoke

Inside of wheel rim

Note: Carefully read instructions for mixing antifreeze solution used. Some products will have a higher freezing point in their natural state than when mixed with water.

WARNING

Disconnect power to the unit before performing any type of service.

Energy Recovery Wheel Maintenance

Annual inspection of the energy recovery wheel is recommended. Units ventilating smoking lounges and other non-clean air spaces should have energy recovery wheel inspections more often based upon need. Inspections for smoke ventilation applications are recommended bimonthly to quarterly until a regular schedule can be established.

Accessing the Energy Recovery Wheel

Access to the wheels on all VER models is provided by a wheel access door. The cassettes can be serviced and inspected by simply sliding them out of the unit as far as is needed. Be sure to disconnect the power wires to the motor before sliding the cassette. The VER-45 and the VER-65 have one wheel. The VER-90 has two wheels which are accessed on opposite sides of the unit.

Removing the Energy Recovery Wheel Segments

Steel retainers are located on the inside of the wheel rim. Push the retainer toward center of wheel, then lift up and away to release segments (see below).

Important! Place retainers back in the original position before rotating the energy recovery wheel, otherwise damage to retainer will occur.

Wheel

Removal

Cleaning the Energy Recovery Wheel

If the wheel appears excessively dirty, it should be cleaned to ensure maximum operating efﬁciency. Only excessive buildup of foreign material needs to be removed. Discoloration and staining of energy recovery wheel does not affect its performance.

Thoroughly spray wheel matrix with household cleaner such as Fantastik® or equivalent. Gently rinse with warm water and using a soft brush remove any heavier accumulation. A detergent/water solution can also be used. Avoid aggressive organic solvents, such as acetone. The energy recovery wheel segments can be soaked in the above solution overnight for stubborn dirt or accumulation.

After cleaning is complete, shake the excess water from the wheel or segments. Dry wheel or segments before placing them back into the cassette. Place wheel or segments back into cassette by reversing removal procedures.

CAUTION

Do not clean energy recovery wheel segments with water in excess of 140ºF (60ºC).

Do not dry energy recovery wheel segments in air in excess of 140ºF (60ºC).

The use of a pressure washer to clean segments is not recommended. Damage could result.

Energy Recovery Wheel Belt

Inspect belts each time ﬁlters are replaced. Belts that look chewed up or are leaving belt dust near the motor pulley may indicate a problem with the wheel. Be sure to inspect wheel for smooth and unrestricted rotation. If a belt requires replacement, contact the local Greenheck

Wheel Belt & Pulley

representative. Instructions for replacement will ship with the new belt.

Energy Recovery Wheel Bearings

In the unlikely event that a wheel bearing fails, access is available through the outdoor air ﬁlter door and through a removable plate in the divider in the unit (accessed through the exhaust air ﬁlter door). Contact the local Greenheck representative for detailed instructions

Wheel Bearing

on how to replace the bearing.

VersiVent Energy Recovery Unit

Page 38

Troubleshooting – Airﬂow

Test and Balance Report

The Test and Balance Report (TAB) is utilized to determine whether the appropriate amount of outdoor air and exhaust air is being supplied and removed from a building, respectively. There are no set rules on what information must be included in a TAB report. As such, if a TAB report indicates that the airflow on a unit is low, prior to contacting the factory, please determine the following information:

Unit #1 Unit #2 Unit #3 Unit #4

Model Number

Serial Number

Nameplate Information

Voltage

Hertz

Phase

Outdoor Air Fan Amps

Exhaust Fan Amps

Outdoor Air Fan Horsepower

Exhaust Fan Horsepower

Design Airflow

Outdoor Air

Exhaust

Measured Airflow

Outdoor Air

Exhaust

Measured Data

Blower Rotation

Outdoor Air Fan RPM

Exhaust Fan RPM

Outdoor Air Fan Amp Draw

Exhaust Fan Amp Draw

Pressure Drop Across Energy Recovery Wheel

Outdoor Air Side

Exhaust Side

Airflow problems can often be tied back to improper ductwork installation. Be sure to install ductwork in accordance with SMACNA and AMCA guidelines.

VersiVent Energy Recovery Unit

Page 39

Troubleshooting – Unit

Symptom Possible Cause Corrective Action

Blown fuse or open circuit breaker.

Defective motor or capacitor. Replace.

Replace fuse or reset circuit breaker and check amps.

Blower fails to

operate

Motor starters

“chatter” or

do not pull in

Motor over amps

Motor starter overloaded. Reset starter and check amps.

Electrical.

Drive.

Control power (24 VAC) wiring run is too long (resistance should not exceed 0.75 ohms).

Incoming supply power is less than anticipated. Voltage supplied to starter coil must be within +10% / -15% of nominal voltage stated on the coil.

CFM too high. Check cfm and adjust drives if needed.

Static pressures are higher or lower than design.

Blower rotation is incorrect. Check rotation and reverse if necessary.

Motor voltage incorrect. Check motor nameplate versus supplied voltage.

Motor horsepower too low.

Shorted windings in motor. Replace motor.

Check for On/Off switches. Check for correct supply voltage.

Check for broken or loose belts. Tighten loose pulleys.

Shorten wiring run to mechanical room or install a relay which will turn unit on/off. Consult Factory for relay information. Increase wire gauge size so that resistance is .075 ohms or less.

Need to increase supply power or use a special control transformer which is sized for the actual supply power.

If higher, ductwork should be improved. If lower, fan rpm should be lower.

See specifications and catalog for fan curves to determine if horsepower is sufficient.

Unit damper not fully open. Adjust damper linkage or replace damper motor.

System static pressure too high.

Blower speed too low.

Fan wheels are operating backwards.

Low airflow (cfm)

Dirty filter or energy wheel.

Leaks in ductwork. Repair.

Elbows or other obstructions may be obstructing fan outlet.

Belt slippage. Adjust belt tension.

Blower fan speed too high.

High airflow (cfm)

Always have a completed Pre Start-Up Checklist, unit Start-Up Checklist, and Optional Accessories Checklist prior to requesting parts or service information.

Filter(s) not in place. Install filters.

Insufficient static pressure (Ps) (airflow resistance).

Improve ductwork to eliminate losses using good duct practices.

Check for correct drives and rpm with catalog data.

For 3-phase, see Direction of Fan Wheel Rotation under Unit Start-Up section.

Follow cleaning procedures in Routine Maintenance section.

Correct or improve ductwork.

Check for correct fan rpm. Decrease fan speed if necessary.

Induce Ps into system ductwork. Make sure grilles and access doors are installed. Decrease fan speed if necessary.

VersiVent Energy Recovery Unit

Page 40

Troubleshooting – Unit

Symptom Possible Cause Corrective Action

One or both

blowers turn off

intermittently and

back on after

about 2 minutes

Exhaust Only frost control sensors are tripping.

Adjust frost temperature sensor set point as needed.

Energy wheel does

NOT turn

Energy wheel runs

intermittently

Air seals are too tight.

“Economizer” sensors are operating.

No power to wheel motor.

Wheel drive belt.

VFD overload. (OL1 on readout)

Wheel motor overloads are tripping, due to rubbing between wheel and air seals.

Fan wheel rubbing on inlet.

Bearings.

Wheel out of balance. Replace or rebalance.

Loose wheel on shaft. Tighten wheel setscrew.

Loose motor or blower sheave. Tighten sheave setscrew.

See Energy Recovery Wheel under Unit Start-Up section.

Adjust temperature or enthalpy set points as needed.

Make sure wheel drive is plugged in. Verify power is available.

Check for loose or broken belts. Replace belts (consult factory).

Refer to VFD section. Compare motor amp rating to setting in VFD. Adjust accordingly.

Recheck air seals, make sure they are not too tight. See Energy Recovery Wheel under Unit Start-Up Section.

Adjust wheel and/or inlet cone. Tighten wheel hub or bearing collars on shaft.

Replace defective bearing(s). Lubricate bearings. Tighten collars and fasteners.

Belts too loose. Adjust belt tension after 24 hours of operation.

Excessive noise

or vibration

Always have a completed Pre Start-Up Checklist, unit Start-Up Checklist, and Optional Accessories Checklist prior to requesting parts or service information.

Belts too tight.

Worn belt. Replace.

Motor base or blower loose. Tighten mounting bolts.

Buildup of material on wheel. Clean wheel and housing.

Bearing and drive misaligned. Realign.

Noise being transmitted by duct.

Loosen to maintain a 3/8 inch deflection per foot of span between sheaves.

Make sure ductwork is supported properly. Make sure ductwork metal thickness is sized for proper stiffness. Check duct size at discharge to ensure that air velocities are not too high.

VersiVent Energy Recovery Unit

Page 41

Troubleshooting – Refrigeration Circuit (optional)

TROUBLESHOOTING NOTE

IMPORTANT

Do not release refrigerant to the atmosphere! If Before any components are changed on the refrigeration system, the cause of the failure must be identified. Further problems will exist unless the true cause or problem is identified and corrected.

required service procedures include the adding or

removing of refrigerant, the service technician must

comply with all federal, state and local laws. The

procedures discussed in this manual should only be

performed by a qualified HVAC Technician.

NOTE: Unit is equipped with a phase loss/phase reversal control. If system does not start, check phase of electrical supply.

Symptom Possible Cause Corrective Action

Open disconnect switch or circuit breaker. Close switch and / or breaker.

Check voltage to contactor coil, transformer, slave relay, system. Replace parts as necessary.

Check for reason and repair. Replace fuse after correcting problem.

Check line voltage. If more than 10% from compressor marking, correcting is necessary.

Motor thermal protector automatically resets. Allow time (2 hrs.) for compressor to cool down so protector will reset. Restart and check for reason overheat occurred.

Check motor for open circuit, short circuit, grounded windings or burn out. Compressor may be seized; check refrigerant. If necessary, replace compressor.

Compressor

will not run

does not

try to start

Compressor contactor not closing.

Blown fuse or tripped breaker.

Low line voltage.

Compressor motor protector open.

Compressor defective.

If manual reset (high pressure), reset switch. (Switch opens at 600 psi and will not reset above

High or low pressure switch open or defective.

Open room thermostat or control (no cooling required).

Loose wiring.

Low refrigerant charge. Check refrigerant pressures.

Compressor starts

but cuts out on low

pressure

Low pressure

switch activates

at 50 psig for R410a

Always have a completed Pre Start-Up Checklist, unit Start-Up Checklist, and Optional Accessories Checklist prior to requesting parts or service information.

Airflow restricted.

Restriction in refrigerant line.

Defective low pressure switch. Replace.

420 psi for R410a. If auto reset (low pressure) does not reset and everything else is OK, replace switch.

Check room temperature. If temperature is proper, wait for thermostat to close.

Check all wire terminals and tighten as necessary.

Check for dirty evaporator coil, dirty filters, dampers closed, iced evaporator coil, improper belt, check motor amps, check duct design.

Check refrigerant pressure, check and adjust thermal expansion valve. If not functioning properly, check for pressure drop across the filter drier.

VersiVent Energy Recovery Unit

Page 42

Troubleshooting – Refrigeration Circuit (optional)

Symptom Possible Cause Corrective Action

Refrigerant overcharge. Check pressures, charge by subcooling.

Condenser fan motor defective. Check fan motor.

Compressor starts

but cuts out on high

pressure switch

High pressure

activates at

600 psig for R410a

Condenser coil inlet obstructed or dirty. Check coil and inlet clearances.

Air or non-condensables in system.

Defective high pressure switch. Replace.

Restriction in discharge or liquid line.

Condensing fan relay not pulling in. Replace.

Low voltage. Check voltage.

Sustained high discharge pressure.

Check high side equalized pressure reading with equivalent outdoor temperature.

Check refrigerant line pressures, check thermal expansion valves.

Check running amperage and conditions described under ‘Low suction pressure’ symptoms.

Compressor cuts out

on thermal overload

Compressor hums,

but will not start

High suction and discharge pressures.

Defective compressor overload.

Improper refrigerant charge. Check subcooling.

Improperly wired. Review wiring schematics.

Loose wiring. Check all connections and wires.

Defective start relay. Replace relay.

Motor windings damaged. Verify amp draw.

Improperly wired. Review wiring schematics.

Low line voltage. Check voltage.

Loose wiring. Check all connections.

Defective start or run capacitor.

Defective relay start. Replace relay.

Check thermal expansion valve setting, check for air in system.

If compressor is hot, allow compressor to cool for two hours. Recheck for open circuit.

Check run capacitor for compressor and fan motor.

Motor winding damaged. Verify amp draws.

Internal compressor mechanical damage. Replace.

Always have a completed Pre Start-Up Checklist, unit Start-Up Checklist, and Optional Accessories Checklist prior to requesting parts or service information.

VersiVent Energy Recovery Unit

Page 43

Troubleshooting – Refrigeration Circuit (optional)

Symptom Possible Cause Corrective Action

Refrigerant overcharge. Check pressures and subcooling.

Compressor noisy

or vibrating

High suction

pressure

Liquid floodback.

Tubing rattle.

Scroll compressor rotating in reverse (3 phase). Rewire for opposite rotation.

Worn or damaged compressor. Replace the compressor.

Improper mounting on unit base. Check that compressor is properly isolated.

Excessive load on evaporator coil.

Compressor is unloaded.

Expansion valve not secured to suction line.

Check thermal expansion valve setting. Check for refrigerant overcharge.

Dampen tubing vibration by taping or clamping. Carefully bend tubing away from contact where possible.

Check for high entering wet bulb temperature. Check for excessive air.

Check head pressure, check thermal expansion valve if not functioning properly, check pressure drop across filter drier.

Check the thermal expansion valve, ensure bulb is insulated.

Check superheat. If superheat is high, then valve is out of control and pegged wide open.

•Checkbulbforcontact. •Adjustvalveforsuperheat. •Replacevalvepowerheadorvalve.

High discharge

pressure

Thermostatic expansion valve pressure limit feature incorrect or inoperative. Overfeeding.

Room load too large. Reduce the load or add more equipment.

Overcharged. Check pressures and subcooling.

Thermal expansion valve setting.

Air inlet to condenser dirty or obstructed.

Condenser fan motor defective. Check condenser fan motor and capacitor.

Too much refrigerant. Remove excess refrigerant.

Non-condensable in system. Remove non-condensable from system.

Dirty condenser coil. Clean condenser coil.

Condenser fan not running or running backwards.

Discharge service valve partially closed. Open valve.

High load conditions. Add more equipment or reduce load.

Check bulb location and clamping. Adjust superheat. Replace expansion valve power head.

Check thermal expansion setting and calibrate superheat.

Check for proper clearances and possible air recirculating.

Check electrical circuit and fuse. Check fan cycling controls.

Always have a completed Pre Start-Up Checklist, unit Start-Up Checklist, and Optional Accessories Checklist prior to requesting parts or service information.

VersiVent Energy Recovery Unit

Page 44

Troubleshooting – Refrigeration Circuit (optional)

Symptom Possible Cause Corrective Action

Refrigerant undercharge. Check pressures and subcooling.

Low suction

pressure

Low discharge

pressure

Blower running backward.

Loose blower, pulley or belts. Check drive pulley alignment, belt tension.

Low entering air temperature (low load condition).

Refrigerant leak.

Evaporator dirty or iced up or airflow restricted.

Plugged liquid line filter-drier. Replace filter-drier.

Improper suction pressure regulator setting. Check setting and correct as required.

Expansion valve defective, superheat too high, or valve too small.

Moisture in system. Reclaim refrigerant, check for leaks, recharge.

Insufficient refrigerant charge.

Defective or improperly adjusted expansion valve.

Low suction pressure. See “Low suction pressure”.

Interchange any two wires from 3 phase disconnect.

Check entering air wet bulb conditions.

Check system for leaks. Repair leaks and add refrigerant.

Check defrost system. Clean the coil. Check fan operation. Check airflow.

Adjust valve for proper superheat or replace the expansion valve if too small or defective.

Check subcooling, check for leak. Repair leak and add refrigerant.

Check superheating and adjust thermal expansion valve.

Faulty condenser temperature controls.

Thermostat location or malfunction.

Improper refrigerant charge. Check subcooling, verify superheat.

Defective high or low pressure control. Check high or low pressure switch.

Liquid floodback. Possible tight bearings, see above.

Compressor short cycles

Always have a completed Pre Start-Up Checklist, unit Start-Up Checklist, and Optional Accessories Checklist prior to requesting parts or service information.

Defective expansion valve. Check thermal expansion valve and superheat.

Poor air distribution. Check ductwork for recirculating.

High discharge pressure. See “High discharge pressure”.

Leaking discharge valves in compressor. See “High suction pressure”.

Low airflow at evaporator(s).

Incorrect unit selection (oversized). Contact factory.

Check condenser controls and reset to obtain desired condensing temperature.

Check thermostat, check heat anticipator setting.

Check blower operation and airstream restrictions.

VersiVent Energy Recovery Unit

Page 45

Troubleshooting – Refrigeration Circuit (optional)

Symptom Possible Cause Corrective Action

Thoroughly defrost evaporator. After defrost, observe level, add oil. Check for leaks. Check lines for proper slope and traps.

Adjust expansion valve for higher superheat. Check crankcase heater.

Low or no

oil pressure

Low oil level (trapped oil in evaporator or suction line).

Excessive liquid refrigerant in the crankcase.

Worn oil pump. Replace the oil pump.

Worn compressor bearings. Replace the compressor.

Compressor

loses oil

Running cycle is

too long or unit

operates

continuously

Loose fitting on oil line or pump housing gasket leaking.

Compressor short cycling. Check low pressure control setting.

Refrigerant leak.

Short cycling. Check low pressure control settings.

Refrigerant flood back.

Improper piping or traps. Verify proper piping slopes.

Refrigeration undercharged. Check subcooling.

Dirty filter or evaporator coil. Check filter, coil and airflow.

Dirty or clogged condenser coil. Check coil and airflow.

Air or other non-condensables in system.

Defective compressor. See “High suction pressure”.

Restriction in suction and liquid line. Check for restrictions in refrigerant circuit.

Control contacts stuck. Check wiring.

Check and tighten system. Check bottom plate or compressor.

Check system for leaks. Repair leaks and add refrigerant.

Check thermal expansion valve setting. Check for refrigerant overcharge.

Check equalized high side pressure with equivalent outdoor temperature.

Excessive load. Add more equipment or reduce room load.

Too low of a system thermostat setting or defective thermostat.

Liquid line

is too hot

Liquid line is

frosted or wet

Suction line

is frosting

Frost on

evaporator coil

Always have a completed Pre Start-Up Checklist, unit Start-Up Checklist, and Optional Accessories Checklist prior to requesting parts or service information.

Refrigerant undercharge. Adjust the charge by subcooling.

High discharge pressure. See “High discharge pressure”.

Restriction in liquid line. Clear restriction upstream of point of frosting.

Insufficient evaporator airflow.

Restriction in suction or liquid line. Restriction upstream of point of frosting.

Malfunctioning or defective expansion valve. Check bulb of thermal expansion valve.

Hot gas bypass valve not functioning properly. Check valve. If defective, replace.

Manual hot gas bypass valve closed. Open valve.

Adjust or replace thermostat.

Check airflow, check filters, check drive for loose parts or belts.

VersiVent Energy Recovery Unit

Page 46

Maintenance Log

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

VersiVent Energy Recovery Unit

Page 47

Maintenance Log

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

VersiVent Energy Recovery Unit

Page 48

Warranty

Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the shipment date. The energy recovery wheel is warranted to be free from defects in material and workmanship for a period of ﬁve years from the purchase date. Any units or parts which prove defective during the warranty period will be replaced at our option when returned to our factory, transportation prepaid. Motors are warranted by the motor manufacturer for a period of one year. Should motors furnished by Greenheck prove defective during this period, they should be returned to the nearest authorized motor service station. Greenheck will not be responsible for any removal or installation costs.

As a result of our commitment to continuous improvement, Greenheck reserves the right to change speciﬁcations without notice.

Greenheck Catalog VersiVent provides additional information describing the equipment, fan performance, available accessories, and speciﬁcation data.

AMCA Publication 410-96, Safety Practices for Users and Installers of Industrial and Commercial Fans, provides additional safety information. This publication can be obtained from AMCA International, Inc. at: www.amca.org.

Phone:(715)359-6171•Fax:(715)355-2399•E-mail:gfcinfo@greenheck.com•Web site: www.greenheck.com