Reznor XBWU11 Installation Manual

INSTALLATION INSTRUCTIONS

FORM RZ-NA-I-XBWU

SUPERCEDES 09-27-13

MAY 29, 2014

OXX-2XERV

EN ERGY RE COV ERY VEN TI LA TOR

INSTALLATION INSTRUCTIONS FOR ROOFTOP STAND ALONE

ENERGY RECOVERY UNIT IN OVER/UNDER DESIGN

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.

I - Ship ping And Pack ing List

Package contains: 1 - Energy Recovery Ventilator Assembly

II - Ship ping Dam age

Check unit for shipping damage. Receiving party should contact last carrier immediately if shipping damage is found.

III - Gen eral

These instructions are intended as a general guide and do not supersede local codes in any way. Authorities having jurisdiction should be consulted before installation.

IV - Re quire ments

When installed, the unit must be electrically wired and grounded in accordance with local codes or, in absence of local codes, with the current National Electric Code, ANSI/NFPA No. 70.

V - Ap pli ca tion

These Energy Recovery Ventilators (ERV) are used in a down discharge manner equipped with field provided balancing damper assembly through the roof. A roof curb must be provided to Rooftop Systems specifications. These wheels conserve energy by mixing warmer air with cooler air in the following manner:

Re cov ery Wheel Mode

The Recovery Wheel mode is accomplished by two blowers providing continuous exhaust of stale indoor air and replacement by equal amount of outdoor air. Energy recovery is achieved by slowly rotating the energy recovery wheel within the cassette frame work. In winter, the ERV adsorbs heat and moisture from the exhaust air stream during one half of a complete rotation and gives them back to the cold,drier intake air supply during the other half rotation. In summer, the process is automatically reversed. Heat and moisture are absorbed from incoming fresh air supply and transferred to the exhaust air stream. This process allows outdoor air ventilation rates to be increased by factors of three or more without additional energy penalty or increase in size of heating or air conditioning systems.

VI - Rig ging Unit For Lift ing

1. Maximum weight of unit is — Varies per Series {300-1200 Lbs.} (Crated)

2. Remove crating.

3. All panels must be in place for rigging.

4. Remove barometric exhaust hood from door marked filter access. Install barometric exhaust hood over exhaust blower outlet.

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Ap plies to Model XBWU

ETL Certified per UL 1995 and CSA 22.2

5. Duct work should be installed into roof curb before installing ERV on curb.

6. Roof curb gasket must be applied to all top surfaces of the curb.

7. Forklift channels must be removed from the base of ERV before setting unit on curb. See Figure 1.

8. Position unit on roof curb and provide service access to ERV control access door and wheel.

FIGURE 1

FORKLIFT CHANNELS

CAUTION

Danger of sharp metallic edges. Can cause injury. Take care when servicing unit to avoid accidental contact with sharp edges.

VII - In stal la tion

1. Attach duct work to duct flanges on roof curb.

2. Remove forklift channels from base of ERV.

3. Set ERV on curb. Verify ERV is positioned on curb properly.

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.

4. Remove barometric exhaust hood from door marked filter access. Install barometric exhaust hood over exhaust blower outlet.

5. Remove ERV control access panel to connect field wiring.

6. Route class II low voltage wire (3 conductor) from thermostat or energy management through small bushing in end panel of ERV. See wiring diagram.

a. Thermostat (dependent) - connect in parallel at

rooftop unit with "G", "C" and "W". Then connect matching color at terminal 1, 2, and 3 respectively on ERV circuit board.

b. Energy Management - provide +24 VAC to "1" and

common, 24 VAC to "2" terminals on ERV circuit board.

c. Thermostat (dedicated) - splice into +24 vac (blue

wire) at (control circuit board) transformer connection run wire to "R" terminal. Then run another wire from "G" terminal to ERV (control circuit board) terminal block #1.

7. All electrical connections must conform to any local codes and current National Electric Codes (NEC) and Canadian Electric Codes (CEC). Refer closely to unit wiring diagram in unit and/or in these instructions for proper wiring connections.

8. Refer to the unit nameplate for minimum circuit ampacity (MCA) and maximum overcurrent protection size (fuse).

9. Electrical data is listed on unit rating plate and motor name plates.

10. Connect line voltage power supply to ERV fuse block in control box of unit from disconnect switch. See

wiring diagram.

11. Ground unit with a suitable ground connection either through unit supply wiring or an earth ground.

Note: Unit voltage entries must be sealed weather

tight after wiring is complete.

12. Remove motor access panels. Locate belts fastened to blower assembly. Install belt onto motor and blower pulley. Adjust motor sheave to correct blower RPM for CFM and external static pressure requirements. See charts in this instruction. Multiple pulley arrangements are available to meet the entire range.

Caution: 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 over loading can occur.

13. Replace access panel onto the ERV unit and secure.

14. Restore power to unit.

15. Cleanup once unit is operating properly, caulk any open joints, holes or seams to make the unit completely air and water tight.

16. Leave this instruction manual with owner or in an envelope to be kept near unit.

VIII - Op er a tion How It Works

The unit contains an Energy Recovery Wheel (ERW) that is a new concept in rotary air-to-air heat exchangers. Designed as a packaged unit for ease of installation and maintenance, only the connection of electrical power is required to make the system operational.

When slowly rotating through counter flowing exhaust and fresh air streams the ERW adsorbs sensible heat and

latent heat from the warmer air stream and transfers this total energy to the cooler air stream during the second half of its rotating cycle. Rotating at 50-60 revolutions per minute, the wheel provides constant flow of energy from warmer to cooler air stream. The large energy transfer surface and laminar flow through the wheel causes this constant flow of recovered energy to represent up to 85% of the difference in total energy contained within the two air streams.

Sensible and latent heat are the two components of total heat. Sensible heat is energy contained in dry air and latent heat is the energy contained within the moisture of the air. The latent heat load from the outdoor fresh air on an air conditioning system can often be two to three times that of the sensible heat load and in the winter it is a significant part of a humidification heat load.

During both the summer and winter, the ERW transfers moisture entirely in the vapor phase. This eliminates wet surfaces that retain dust and promote fungal growth as well as the need for a condensate pan and drain to carry water.

Because it is constantly rotating when in the air stream, the ERV is always being cleaned by air, first in one direction then the other. Because it is always dry, dust or other particles impinging on the surface during one half cycle, are readily removed during the next half cycle.

During the heating season, when outdoor air temperatures are below 15oF, it is recommended to use the (optional) low ambient kit (field installed).

Low Ambient Kit is appropriate for climates with limited HVAC system operation when outdoor temperatures are below 10oF.

The frost threshold is the outdoor temperature at which frost will begin to form on the ERV wheel. For Energy Recovery Ventilators, the frost threshold is typically below 10oF. Frost threshold is dependent on indoor temperature and humidify. The table shows how the frost threshold temperatures vary depending on indoor conditions.

FROST 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. Where outdoor temperatures may drop below the frost threshold during the ERV operational hours, exhaust only frost control option is available.

Low Am bi ent Kit (Op tional)

Low Ambient Kit turns off the supply blower when outdoor temperatures fall below the frost threshold. The exhaust only thermostat set points are field adjustable. Supply fan operation is automatically restored when the exhaust air temperature rises above the thermostat set point. Provisions for introducing make-up air into the building when the supply blower is off to avoid depressurization should be considered.

Re cov ery Wheel Mode

On a thermostat call for blower operation in heating, cooling or continuous blower, the ERW will rotate between fresh air and exhaust air streams. Both the fresh air and exhaust air blowers will also be operating to overcome the air resistance of the ERV.

IX - Sys tem Check

1. Disconnect main power.

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2. Turn to "Cont" for blower operation on thermostat

controlled models.

3. Restore power to unit. Observe ERV wheel rotation

and both fresh air and exhaust air blowers while operating.

Note: If Low ambient kit is used the jumper between

TB37-5 & TB37-6 should be removed. Also if system check out is being conducted at low ambient temperatures, technician should be aware that this kit can cause system not to operate.

4. Verify that the ERV (3) three phase blower motors are

phased sequentially ensuring correct rotation and operation.

a - Disconnect power. b - Reverse any two field power leads to the ERV. c - Reapply power.

5. Verify that both blower motors are operating under

their full load AMP rating (FLA). The FLA can be found on each motor and the unit nameplate

A - Re turn Damper Set tings

Manually adjust position of field installed dampers to balance air flow.

B - Air 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.

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.

X - Main te nance

1. All motors use prelubricated sealed bearings; no

further lubrication is necessary.

2. Make visual inspection of motors, belts and wheel

rotating bearings during routine maintenance.

3. Eight pie-shaped segments are seated on stops

between the segment retainer which pivots on the wheel rim and is secured to the hub and rim of the wheel. Annual inspection of the self cleaning wheel is recommended. With power disconnected, remove ERV access panels (rear) and unplug [J150 & P150]

(Refer to wiring diagram in this instruction manual). Remove segment and wash with water

and/or mild detergent.

4. To install wheel segments follow steps A through E .

See Figure 2. Reverse procedure for segment removal.

a. Unlock two segment retainers (one on each side of

the selected segment opening.

WHEEL RIM

SPOKE

SEGMENT RETAINER CATCH

HUB

FIGURE 2

SEGMENT RETAINER

SEGMENT

b. With the embedded stiffener facing the motor side,

insert the nose of the segment between the hub plates.

c. Holding segment by the two outer corners, press

the segment towards the center of the wheel and inwards against the spoke flanges. If hand pressure does not fully seat the segment, insert the flat tip of a screw driver between the wheel rim and outer corners of the segment and apply downward force while guiding the segment into place.

d. Close and latch each segment retainer under

segment retaining catch.

e. Slowly rotate the wheel 180o. Install the second

segment opposite the first for counterbalance. Rotate the two installed segments 90o to balance the wheel while the third segment is installed. Rotate the wheel 180o again to install the fourth segment opposite the third. Repeat this sequence with the remaining four segments.

XI - Pul ley Kit In stal la tion

The units are shipped from the factory at the low static setting. Pulley kits are available for the medium and high static settings. To install a pulley kit.

1. Check content of pulley kit, if pulley kit contains: a. An adjustable sheave and a fixed pitch pulley then

remove belt and both motor and blower pulley

b. An adjustable sheave then remove the motor

pulley.

c. A fixed pitch pulley then remove the blower pulley.

2. Replace pulley(s) with the pulley(s) from pulley kit.

Make sure each pulley is installed with a key. Tighten the set screw on the pulley(s) to 100 in.lb.

3. Install the belt that came with the pulley kit. Tension

belt as explained in the blower speed adjustment section.

4. Check the speed of the blower. Adjust the motor

sheave to increase or decrease the speed of the blower. See blower adjustment section.

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Stand Alone ERV’S For Over and Under Duct Arrangements

Fea tures and Notes

1. Stand alone design allows higher levels of outdoor air to be introduced into the conditioned space.

2. Static test ports provided to verify intake and exhaust CFM.

3. Balancing damper(s) is field provided when connected to ductwork. System may not operate properly without balancing damper.

4. Roof curbs are available for the ERV’s.

5. See blower performance charts for airflow at various E.S.P.

6. Filter rack with 2” pleated filters included.

Roof Curbs (Op tion Codes)

Size 14" 24"

11 CJ51-11 CJ52-11

20 CJ51-20 CJ52-20

28 CJ51-28 CJ52-28

36 CJ51-36 CJ52-36

46 CJ51-46 CJ52-46

62 CJ51-62 CJ52-62

ERV with Hori zon tal Duct work

(bal anc ing damper(s) field sup plied)

ERV Data Di men sional Data

Size CFM Range A B C D E F G H I J K L

11 300-1100 56.75 32.13 39.50 11.00 27.00 6.50 10.00 2.56 1.00 11.00 55.00 30.25

20 1200-2000 54.38 37.25 37.50 12.00 30.00 8.00 4.00 3.63 1.50 20.32 52.75 35.50

28 1200-2800 60.00 42.62 43.56 14.00 32.00 9.56 4.50 5.31 1.50 18.32 49.50 41.00

36 2000-3600 60.00 46.69 57.37 16.50 39.50 12.13 6.38 3.59 5.88 18.32 55.75 41.81

46 3000-4600 60.00 52.69 57.37 16.50 39.50 12.13 6.38 6.59 5.88 18.32 55.75 47.81

62 4600-6200 72.00 70.88 63.63 19.50 39.50 12.13 6.50 15.69 5.88 18.32 67.75 66.00

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