PennBarry D11 Installation Manual

INSTALLATION INSTRUCTIONS
STAND ALONE ERV
DXX-2ERV
D-SE RIES
ENERGY RECOVERY VENTILATOR SERIES D11, D20, D28, D36, D46, D62, D80 & D12
INSTALLATION INSTRUCTIONS FOR ENERGY RECOVERY VENTILATOR (FIXED)
FOR STAND ALONE ROOFTOP APPLICATION
Energy recovery COMPONENT certified to the AHRI Air-to-Air Energy Recovery Ventilation Equipment Certification Program in accordance with AHRI Standard 1060-2000. Actual performance in packaged equipment may vary.
ETL Certified per UL 1995 and CSA 22.2
OCTOBER 6, 2015
I - Ship ping and Pack ing List
Package contains:
1 — Energy Recovery Ventilator Assembly 1 — Assembled Exhaust Hood
II - Shipping Damage
Check the unit for shipping damage. Receiving party should contact last carrier immediately if shipping damage is found.
III - General
These instructions are intended as a general guide and do not supersede local codes in any way. Authorities having jurisdiction should be consulted before installation.
IV - Requirements
When installed, the unit must be electrically wired and grounded in accordance with local codes or, in absence of local codes, with the current National Electric Code, ANSI/NFPA No. 70.
V - Application
These Energy Recovery Ventilators (ERVs) are used in a down discharge manner equipped with a field provided balancing damper assembly through the roof. A roof curb must be provided by contractor to manufacturers specifications. These ventilators conserve energy by transferring humidity and heat energy across two opposing air streams using a rotary heat exchanger (the energy recovery wheel). This process works in the summer by rejecting heat energy from incoming intake air and in the winter by conserving heat energy from the exhaust air, allowing outdoor ventilation rates to be increased by factors of three or more without additional energy penalty or increase in size of heating or air conditioning systems.
VI - Rigging for lifting
1. Maximum weight of the unit varies per series (300-1200 lbs crated)
2. Remove crating
3. All panels must be in place for rigging.
4. Remove box containing screws and accessories from the Controls section.
5. Duct work should be installed into roof curb before installing ERV on curb.
6. Roof curb gasket should be applied to all top surfaces of the curb. (refer to roof curb install instructions).
7. Forklift channels (if used) must be removed from the base of the ERV before setting unit on curb. See
Figure 1.
8. Attach lifting straps to the provided lifting lugs on the top 4 corners of the D-11 through D-62 units, on D-80 and D-120 units cutouts are provided on the bottom 4 corners for attachment of lifting straps.
9. Position unit on roof curb being sure to provide service access to ERV control access door and wheel.
WARNING
Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch(es). Unit may have multiple power supplies.
CAUTION
Danger of sharp metallic edges. Can cause injury. Take care when servicing unit to avoid accidental contact with sharp edges.
FIGURE 1
FORKLIFT CHANNELS
PAGE 1
VII - Installation
1. Install exhaust hood assembly shipped with ERV on pallet using screws provided in accessory box. On units with motorized exhaust damper connect Plug (P.161) to jack after removing PK-3 jumper before attaching hood with screws. See Figure 2.
FIGURE 2
2. Remove ERV control access panels to connect field wiring.
Low Voltage
3. Route Class II low voltage wire (3 conductor) from thermostat, relay, or Energy Management through small bushing provided in the end panel in the ERV. See Figure 3 for location of penetration.
THERMOSTAT PENETRATION
HIGH VOLTAGE KNOCKOUT
FIGURE 3
5. On units with Variable Frequency Drives a separate terminal strip is provided to connect low voltage (0-10 VDC) controls [field supplied] for the Drives.
High Voltage
6. All Electrical connections must conform to any local codes and current National Electric Codes (NEC) or Canadian Electric Codes (CEC). Refer closely to unit wiring diagram in the unit and/or in these instructions for proper wiring connections.
7. Refer to unit nameplate for minimum circuit ampacity (MCA) and maximum overcurrent protection size (fuse).
8. Electrical data is listed on unit rating plate as well as the motor name plates.
9. Connect line voltage power from field installed power disconnect to ERV fuse block in the control box of the unit. Use provided knockout on outside panel next to controls section. See Wiring Diagram pg???
10. Ground unit with suitable ground connection either through unit supply wiring or to an earth ground.
Note: Unit voltage entries must be sealed weather
tight after wiring is complete.
11. Remove motor access panels, check that blowers have belts in place and that motors spin freely. Blower RPM can be adjusted to meet CFM and external static pressure requirements by adjusting the sheave on the blower motors and by replacing the pulley kits on units ordered without variable frequency drives. Multiple pulley arrangements are available from the manufacturer to meet the entire range of the units CFM options.
Caution: Blower speed must be adjusted for the given
external static pressure and airflow (CFM) requirements. If blower speed is not adjusted for conditions, possible motor overloading can occur.
12. Unit Startup. Turn on power disconnect, turn on unit either from controls or by Jumping 24v+ from transformer (blue low voltage wire) to terminal #1. Check that motors are spinning the right direction (3 phase units only) that the enthalpy wheel is spinning and that motorized intake air and exhaust dampers are opening.
If unit is operating properly proceed to next step, if not operating properly See Trouble shooting guide on Page 4.
13. Clean up, caulk any open joints, holes or seams to make the unit completely air and water tight. Remove any jumpers, replace all access panels on the unit and secure.
14. Leave this instruction manual with the owner or in an envelope near the unit.
See System Check or Trouble shooting guide for further information on the proper operation of the ERV.
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VIII - Stand Alone ERV Controls Schemes Dependent options Thermostat: This is the standard way to wire an ERV,
when the ductwork of the stand alone ERV is attached to the ductwork of a single AC system the controls of the ERV should be wired in parallel with the controls with "G" to 1, "C" to 2 and "W" to 3. The ERV will operate when ever the RTU's blower is operating.
Energy Management – Building Management Systems: The ERV needs a 24 Volt AC signal to operate, connect the 24V+ to 1 and the 24V C to 2, the unit can be operated off of a relay or BMS controller if necessary.
Dedicated options
When using a control method that does not involve an outside 24V controls signal power can be borrowed from the unit's transformer for short thermostat wire runs. Any run over 150' however should be powered by a separate transformer.
Thermostat: When using an ERV to service a large area with multiple AC units or when not tying directly into the ductwork of a single AC system the ERV can be run off of its own Thermostat. Splice the 24V+ wire "R" onto the XFORMER + terminal of the ERV control board, then wire "G" and "C" onto terminals 1 and 2 respectively, program Thermostat to energize G when space is occupied.
CO2 Sensor/ Transmitter: An ERV can be wired to a wall mounted CO2 Sensor/ Transmitter with relay like Johnson Controls CD-WR0-00-0 (or CD-WRD-00-0) in order to operate the ERV when ventilation is required due to high CO2 levels. This type of transmitter has an adjustable set point, and a relay that the 24V+ signal can be wired into and "G" wire can be wired out of. "G" should be wired to #1 terminal. The ERV will then turn on and provide fresh air to the space to lower CO2 levels.
Quickstep: Units equipped with the Quick Step controls option use an onboard microprocessor, factory installed CO2 sensor and variable frequency drives to modulate airflow through the ERV to control for Carbon Dioxide. To operate the unit enter the Supply and Exhaust CFM values (they do not have to be the same value) into the Quick Step flexstat control along with maximum CO2 level and the controls will modulate the blowers to ensure CO2 levels are not above set point.
ON/OFF switch or Timer: Wire 24V+ from transformer onto the input of the switch and connect the output of the switch to terminal 1 on the control board. The ERV can be turned on manually or be set to turn on at a regular schedule when the building is occupied.
IX – Operation How It Works.
The unit contains an energy recovery wheel (ERW) that is a revolutionary concept in rotary air-to-air heat exchangers. Designed as a packaged unit for ease of installation and maintenance, only the connection of electrical power is required to make the system operational.
When slowly rotating through counter flowing exhaust and fresh air streams the ERW absorbs sensible heat and latent heat from the warmer air stream in the first half of its rotation and transfers this total energy to the cooler air stream during the second half of this rotating cycle.
Rotating at 50-60 RPM, the ERW provides a constant flow of energy from the warmer to the cooler air stream. The large energy transfer surface and laminar flow through the ERW causes this constant flow of recovered energy to represent up to 85% of the difference in total energy contained within the two air streams.
Sensible and latent heat are the two components of total heat, sensible heat is energy contained in dry air and latent heat is the energy contained within the moisture of the air. The latent heat load from the outdoor fresh air on an air conditioning system can often be two to three times that of the sensible heat load and in the winter it is a significant part of a humidification heat load.
During both the summer and the winter, the ERW transfers moisture entirely in the vapor phase. This eliminates wet surfaces that retain dust and promote fungal growth as well as the need for a condensate pan and drain to carry water.
Because it is constantly rotating when in the air stream, the ERW is always being cleaned by air, first in one direction and then the other. Because it is always dry, dust or other particles impinging on the surface during one half of the cycle are readily removed during the next half of the cycle.
During the heating season, when outdoor air temperatures are below 15oF, it is recommended to use the (optional) low ambient kit.
Optional Kits
Motorized Intake Air Damper
This damper mounts inside the outdoor air intake hood, it opens when the ERV supply blower is energized and closes when de-energized.
Motorized Exhaust Air Damper
Damper mounts inside the exhaust air hood, it opens when the ERV is energize and closes when the ERV is de-energized.
Pressure Sensors
Measurement devices (Magnahelics) on ERV that measure pressure across the energy recovery wheel.
Rotation Sensor A magnetic sensor and logic board that measure pulses from a magnet on the spinning energy recovery wheel. A lack of measured pulses after initial start up results in an alarm. The alarm can be wired into building management hardware or to a thermostat with alarm switch terminals, it will warn that the wheel has stopped spinning, but does not otherwise effect operation.
Stop, Start, Jog [Climate Smart]
This option adds an Economizer or free cooling mode to the ERV. The wheel stops spinning to allow air to pass without energy transfer, starting and spinning intermittently in order to keep the wheel clean.
Low Ambient Kit
Prevents frost buildup on energy recovery wheel by terminating intake air when the discharge air temperature falls below a set level. Intake blower operation resumes after a 16oF rise above the field adjustable set point.
The frost threshold is the outdoor temperature at which frost will begin to form on the ERV wheel. For energy recovery ventilators, the frost is typically below 10oF. Frost threshold is dependent on indoor temperature and humidity. The table shows how the frost threshold temperatures vary depending on indoor conditions.
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FROST THRESH OLD TEM PER A TURE
IN DOOR RH AT 70oF
20% 0oF
30% 5oF
40% 10oF
FROST THRESH OLD
TEM PER A TURE
Because energy recovery ventilators have a low frost threshold, frost control options are not necessary in many climates. The Low Ambient Kit is available for units installed where outdoor temperatures may drop below the frost threshold during the ERV operational hours.
Filter Racks/ Filter Options
Stand alone units come with return air filters standard, MERV 8, 11, or 13 filters can be ordered with the unit. Supply air filter racks can be added as an option with the same efficiency filter options.
Dirty Filter Switches
Pressure differential switches that can be hooked up to an alarm to alert when pressure drops across a filter bank indicating dirty or clogged filter, they do not otherwise effect operation.
Wheel Type
While the standard energy recovery wheel absorbs both sensible and latent heat a sensible only wheel can be ordered for applications where the sensible portion of the heat load needs to be removed from a space without returning the humidity.
Smoke Detector
Smoke detectors can be factory ordered with the ERV, a qualified technician needs to field wire the smoke detector into the controls to break common in case of alarm.
CO2 Sensor See Quickstep in Controls schemes. A factory installed Co2 sensor can be added to the unit to adjust ventilation on a CO2 parts per million demand. This sensor is mounted next to the return air inlet and is not a relay, it only provides feedback to the quick step controls to adjust motor speed and is not suitable to turn the unit on and off on CO demand.
X – System Check
1. Disconnect main power
2. On units controlled by thermostats turn T-stat fan switch to "On". Otherwise jump 24v+ to terminal #1.
3. Restore power to unit, observe ERV wheel rotation and both fresh air and exhaust air blowers.
Note: If the low ambient kit is used the jumper between
terminals 5&6 should be removed and replaced with blue and yellow wires for the sensor. If system check out is being done at low ambient temperatures this kit can cause the unit not to operate. Under these conditions jump terminals 5&6.
4. Verify the ERV three phase blower motors are phased sequentially ensuring correct rotation and operation. If both blowers are running backwards:
A. Disconnect Power.
B. Reverse and two high voltage line in wires on the
ERVs fuse block.
C. Reapply Power.
Note: Blower Motor rotation is checked in factory, do
not switch wires at contactors or on motors if blowers are spinning backwards at startup.
5. Verify that both blower motors are operating under their full load AMP rating (FLA). The FLA can be found on each motor and on the unit's name plate.
6. Verify that the fresh air and exhaust air motorized dampers are opening and closing when unit turns on/off.
Note: If unit is not operating properly refer to
troubleshooting guide.
7. Return damper settings. When tied into an HVAC system manually adjust the position of the field installed dampers to balance Air flow.
8. Static test ports are provided to verify intake and exhaust CFM, these ports can also be used with a temperature probe to verify temperature transfer through the wheel.
Adjustment to the blower speed is accomplished by changing the sheave setting on both fresh air and exhaust air blowers.
Flow / Blower Speed Ad just ment
Blower speed selection is accomplished by changing the sheave setting on both fresh air and exhaust air blowers. To set ERV for the required air flow (CFM), the external static pressure applied to the ERV (duct static) must be known. See the CFM vs External Static Pressure chart for the appropriate unit to determine the correct blower RPM for the specified CFM and External Static Pressure.
After blower speed adjustments have been made. Ensure that when the belt is replaced it is tensioned correctly. The motor mounting plate can be adjusted to tension the belt. If using a belt tension checker, adjust the span to the appropriate setting and check the belt defection force. The belt deflection force should be between 5-8 lbs or the lowest tension at which the belt will not slip under peak load conditions.
2
1. Disconnect main power to unit before making adjustment to economizer and/or ERV unit.
2. Replace ERV control access cover.
3. Set thermostat to normal operating position.
4. Restore power to unit.
XI - Se quence of Op er a tion
1. The thermostat or Building Management System (BMS), sends a 24 Volt AC signal to the HVAC system for cooling, heating, fan only or ventilation operation.
2. The ERV is activated simultaneously with the blower of the AC system. The intake air blower, the exhaust blower and the enthalpy wheel motor of the ERV are activated, these motors will remain energized as long as the blower in the AC system is energized and the outdoor conditions are adequate for energy recovery.
3. If the optional motorized intake air damper is present, the damper must open causing a proving switch to close in order to energize the intake air blower (10-20 seconds after the exhaust blower and enthalpy wheel have started).
4. If the optional low ambient kit is present, and the temperature leaving the exhaust side of the enthalpy wheel is lower than the field adjusted set point on the
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temperature sensor, the optional motorized fresh air damper will close and the intake blower will de-energize. The exhaust blower and enthalpy wheel motor will continue to operate until the temperature sensor has a 16F rise, at this point the enthalpy wheel should be defrosted and the optional motorized damper will open and the fresh air blower will reactivate.
5. If the start, stop, jog [Climate Smart] option is present and outside conditions are adequate for free cooling the enthalpy wheel motor will stop for 10 minutes to allow for cool air to enter the building. It will then start or jog the wheel for 1 minute to keep dirt from building up on the wheel.
XII - Trou ble Shoot ing guide ERV will not op er ate:
1. Quick check items.
A. Verify that the door switch is closed, the switch
must be in the closed position in order to power the control board.
B. Verify 24V power to the control board at terminals
Xformer + & -. If voltage is low check high voltage into the unit (sec 2-A) and check that the T-1 wire from the high voltage into the step down transformer is on the correct terminal (208v-230v-460V) for the units voltage.
C. Verify 24V to the control board's terminal strip at
T-1 (G) and T-2 (Com) in Fan or Cool or T-2 (Com) and T-3 (W) in Heat. These terminals must be
powered by an external power source to operate the ERV.
A jumper from Xformer + to T-1 can be used to test operation of the ERV if an external 24V controls signal is not available.
1. Verify high voltage to ERV
A. Verify that the unit has the proper voltage in at
terminals L1, L2 and/or L3 at the fused high voltage connection terminal block. Voltage specifications are on the units name plate.
B. Verify that the fuses are good, (check voltage
across fuses with power on, voltage should be 0) replace any bad fuses.
ERV Has Power, But Motors Are Spinning Backwards
1. Motors are checked for proper rotation at the factory, if the motors are spinning backwards after install reverse the phase by switching two wires on the high voltage IN terminals.
2. If the motor is spinning backwards after replacement switch the L1 & L2 wires connected inside the motors access panel. Do no rewire unit.
*Many of motors used in production of the ERVs are multi voltage (230/460V) motors. When replacing motors or diagnosing a motor that won't start. Care should be taken to make sure the wires inside the motors access panel are connected securely and in the proper configuration.
ERV Has Power, But the Enthalpy Wheel Does Not Spin (Start Stop Jog #1)
1. If the unit has the Start, Stop, Jog option installed the enthalpy wheel motor will turn off for 10 minute intervals when outside conditions are optimal for free
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cooling, the fresh air and exhaust blowers will continue running. The Start, Stop, Jog control board has a white test button that when pressed will bypass the boards logic and turn the enthalpy wheel on. See Start, Stop, Jog in Options/Accessories troubleshooting for further information.
2. With the power off, check that the wheel belt is in place and tight.
3. Check for 24 volts between terminals Exhaust (K163) A&B, if the unit doesn't have Start, Stop, Jog the relay is connected directly to the Exhaust A and B terminals on the control board. If terminals 1&2 or 3&2 are energized with 24V, there is 24V in to Xformer + & - , and there is no voltage to Exhaust A&B the board is bad.
4. If there is 24 Volts at Exhaust A&B trace wires to the enthalpy wheel relay, check terminals A&B on the Relay for 24 Volts, check for high voltage power into and out of the relay. If the relay is energized/closed and no power is passing from terminals 7 to 4 or 9 to 6 the relay is bad.
5. You can jump the enthalpy wheel relay to test its operation by running a jumper from the 24v out on the transformer (blue wire) to the A terminal on the relay after removing the pink wire.
6. If the relay is closing and there is proper voltage between terminals 4&6 on the relay check the wheel's motor for proper voltage by using a multi-meter at Plug P-150 next to the enthalpy wheel motor.
A. If voltage is present and this is a single phase
motor (most units) check the motor's capacitor.
B. If the capacitor is bad replace the capacitor,
continue testing the motor
C. If proper voltage is present and the capacitor is
good check the wires into the motor for continuity, if there is no continuity through the windings a wire connection is loose or the motor is bad, check wire connections between harness and windings, if connections are good the motor is bad, replace motor.
ERV Has Power But the Exhaust Blower Does Not Operate
1. With power off. On units with belts, check that the blower's belt is tight and in place, if it is loose adjust the motor or sheave to tighten it, if it is broken replace it.
2. Check the contactor (K-163) to see if the issue is with high voltage or low voltage, if the contactor is closed check the motor. If it is open, push closed to check that the motor starts then check controls
3. Check for 24 Volts between Exhaust A&B terminals on the control board.
A. If the controls are calling for operation but there are
not 24 Volts between Exhaust A&B the board is bad.
B. If the controls are calling for operation and there
are 24 Volts between Exhaust A&B check the yellow wire for direct connection to the proper contactor (K-136), then check the pink wire for continuity through the field installed exhaust damper motor (if option was chosen) or the factory installed plug (PK-3) at the Jack (J-161) located in the exhaust blower section.
3. If contactor is closed check voltage to the motor by testing wires at Plug P-151, proper voltage is listed on the unit's information tag. If there is proper voltage to the motor and the motor is not spinning the motor is bad. With single phase units check the capacitor, if capacitor is bad replace it then continue checking the motor.
ERV Has Power But The Intake Air Blower Does Not Operate
1. With power off. On units with belts, check that the blower's belt is tight and in place, if it is loose adjust the motor or sheave to tighten it, if it is broken replace it.
2. Check the contactor (K-164) to see if the issue is with high voltage or low voltage. If the contactor is closed check the motor. If it is open, push closed to check that the motor starts, then check controls.
3. If the contactor is open check for 24 Volts between Fresh A&B terminals on the control board.
A. If the controls are calling for operation and there is
no voltage between Fresh A&B check terminals 5&6 to see if low ambient kit is installed (blue and yellow wires installed instead of a jumper), jumping terminals 5&6 will bypass the low ambient sensor and energize terminals Fresh A&B. See Low Ambient Kit in Options/Accessories troubleshooting for further information.
B. If the controls are calling for operation and there is
no voltage between Fresh A&B and there is continuity between terminals 5&6 then the board is bad.
C. If the controls are calling for operation and
terminals Fresh A&B are energized but the contactor is not energizing, check the yellow wire from terminal Fresh B to contactor (K-164), check the orange wire for continuity from terminal Fresh A through factory installed fresh air damper plug (P-160) to contactor. In models without a fresh air damper option there should be an orange jumper between pins 3&4 on the P-160 plug, when the fresh air damper option is chosen these wires connect to an end switch that is closed by a cam when the fresh air damper opens. See Sequence of Operations.
1. If contactor is closed check voltage to the motor by testing wires at plug P-148, proper voltage is listed on the unit's information tag. If there is proper voltage to the motor and the motor is not spinning the motor is bad. With single phase units check the capacitor, if capacitor is bad replace it then check the motor.
ERV Has Power But The Motorized Fresh Air Damper Does Not open
1. Verify 24V in between terminals 1&2 or 3&2
2. Check voltage at junction J-56 on the ERV control board, there should be 24V between J-56 1&2 during normal operation, If the unit has a low ambient kit installed and temperatures are low the controls de-energize J-56 and Fresh K-164 terminals on the control board, jump Terminals 5&6 on the Terminal strip to bypass see Low Ambient Kit in Options/Accessories Troubleshooting for further information.
3. If there is voltage at the control board check for 24V at plug P-160 between pins 1&2
4. If there is voltage at P-160 make sure the damper linkage isn't binding and that the wires are attached to the actuator firmly. If the actuator still doesn't move when 24V is applied replace the actuator.
ERV Has Power But The Motorized Exhaust Air Damper Does Not Open
1. Verify 24V In between terminals 1&2 or 3&2
2. Check voltage at Exhaust A&B on control board
3. If there is voltage at Exhaust A&B on the control board, trace wires to the exhaust blower compartment and plug P-161, Check for 24V between Pins 1&3.
4. If there is 24V at plug P-161 make sure the field connected P-161 plug for the damper is inserted firmly into J-161, that the damper linkage isn't binding and that the wires are connected firmly to the actuator. If the damper actuator still does not move the actuator is bad.
Options and Accessories Troubleshooting
Start, Stop, Jog [Climate Smart]
The Start, Stop, Jog kit is an optional control board with temperature and/or enthalpy sensor(s) that stops the enthalpy wheel from spinning (and transferring heat) when temperature conditions are conducive for free cooling. The board will spin the wheel intermittently in 10 min off 1 min on intervals to keep dust from building up on the surface.
All units shipped with the Start, Stop, Jog option installed have the temperature and enthalpy sensors installed, and the jumper (J9) set to T(emp). A qualified tech can adjust the setting to E(nthalpy) only or Temp and Enthalpy by adjusting the jumper (J9).
The factory set points to allow for free cooling during ventilation are 40F-70F, but they can be field adjusted to narrow the band by adjusting two potentiometers while measuring VDC between the Com & High or Com & Low terminals (0 VDC = 40 degrees, low set point, 5 VDC = 70 degrees, high set point).
Low Ambient Kit
The low ambient kit is an optional temperature probe on a normally closed switch that closes the fresh air damper and turns off the fresh air blower when temperatures in the blower compartment suggest a frosted enthalpy wheel. The adjustable sensor is factory set for 20F. The sensor is mounted in the blower compartment with its probe near the blower's inlet, it is wired into the terminal strip 5&6 terminals.
It can be tested in hot weather by turning the dial up to a higher temperature and checking to see if the normally closed relay opens. In cold weather if the "R" terminal and "W" terminal in the sensor show an open circuit the bulb can be warmed above the set-point at which point the relay should close.
Dirty Filter Switch
Dirty filter switches are an optional kit that put an adjustable pressure switch with the Low inlet on the blower side of the filter and the High inlet connected to the far side of the filter via tubing. A dirty filter moves less air lowering the pressure on the fan side Low inlet closing the normally open sensor switch and allowing an alarm. The sensor(s) are prewired into their own terminal strip and can be field wired in series (normally closed), in parallel (normally open) or individually to an alarm device.
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