Greenheck VER-65 Installation Manual

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.

VersiVent Energy Recovery Unit

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.

VersiVent Energy Recovery Unit

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

VersiVent Energy Recovery Unit

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.

VersiVent Energy Recovery Unit

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.

VersiVent Energy Recovery Unit

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

VersiVent Energy Recovery Unit

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

VersiVent Energy Recovery Unit

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

VersiVent Energy Recovery Unit

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.

VersiVent Energy Recovery Unit

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.

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

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

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

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

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

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