Venmar ERV5000-10000, HRV3000-10000 Installation, Operation And Maintenance Instructions Manual

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Page 1

Aston-built Products

Custom-built Dedicated Outdoor Air Systems

Installation, Operation and Maintenance Instructions Manual

Capacities: 1,000 to 300,000+ cfm Model: EnergyPack®, ERV5000–10000 (indoor/ outdoor), HRV3000–10000 (indoor/outdoor)

Page 2

Table of Contents

Nomenclature ......................................................................................................................................................................3

Safety Considerations .........................................................................................................................................................8

General Information ...........................................................................................................................................................8

Recommended Spare Parts ........................................................................................................................................... 8

Unit Inspection on Arrival.............................................................................................................................................9

Unit Application Limitations ........................................................................................................................................9

Installation ...........................................................................................................................................................................9

Unit Location Requirements .........................................................................................................................................9

Roofcurbs Supplied by Venmar CES (External Applications Only) ...........................................................................10

Roofcurbs Supplied by Others .................................................................................................................................... 10

Rigging, Lifting and Assembling ................................................................................................................................ 11

Hood Installation.........................................................................................................................................................17

Indoor Suspended Installation ...................................................................................................................................17

Field Fabricated Ductwork..........................................................................................................................................18

Electrical Connections ................................................................................................................................................. 19

Coil, WSHP or Humidiﬁer Piping Connections ..........................................................................................................20

Condensate Drain Trap and Lines ..............................................................................................................................21

Gas Connections .......................................................................................................................................................... 21

Refrigerant Systems ....................................................................................................................................................21

Start-up .............................................................................................................................................................................. 21

Pre Start-up Check.......................................................................................................................................................21

Start-up Procedure ...................................................................................................................................................... 23

Airﬂow Balancing........................................................................................................................................................24

Maintenance ......................................................................................................................................................................25

Long-term Storage Maintenance Procedures ............................................................................................................25

Maintenance Summary Chart .....................................................................................................................................25

Energy Recovery Wheel ..............................................................................................................................................25

Flat Plate Heat/Enthalpy Exchangers .........................................................................................................................29

Heat Pipe Heat Exchangers.........................................................................................................................................29

Refrigerant Systems ....................................................................................................................................................30

Dampers .......................................................................................................................................................................31

Belt Driven Fans...........................................................................................................................................................32

FANWALL

Motors..........................................................................................................................................................................39

Filters............................................................................................................................................................................39

Coils ..............................................................................................................................................................................39

Controls........................................................................................................................................................................40

Troubleshooting ..........................................................................................................................................................40

Appendix A: Roofcurb Generic Assembly Instructions ....................................................................................................41

Appendix B: Water Source Heat Pump (WSHP) Piping, Installation, Maintenance and Troubleshooting ..................42

Appendix C: Positive and Negative Pressure Trapping ................................................................................................... 47

Appendix D: Gas-ﬁred Furnace Modules Installation and Maintenance .......................................................................48

Tubular Gas-ﬁred Duct Furnace Module ...................................................................................................................48

IG Series Drum and Tube Gas-ﬁred Duct Furnace Module ....................................................................................... 62

Appendix E: EnergyPack

Appendix F: HEPA Filter Installation ................................................................................................................................ 90

Appendix G: Electric Heating Coil and Controls Information ........................................................................................92

Appendix H: Extended Dormant Unit Maintenance Procedure .....................................................................................94

Appendix I: EnergyPack®, ERV5000–10000 and HRV3000–10000 Maintenance Summary Chart .................................97

Appendix J: Measuring and Adjusting V-belt Tension ...................................................................................................98

Appendix K: Energy Recovery Wheel Multi-link Drive Belt Instructions .......................................................................99

Appendix L: Fan Bearing Lubrication Schedule .............................................................................................................100

Appendix M: FANWALL® Inlet Cone Alignment ...........................................................................................................101

Appendix N: Filter Resistance and Latches ....................................................................................................................102

Appendix O: Troubleshooting ........................................................................................................................................103

Appendix P: Adjusting Refrigerant Charge ................................................................................................................... 105

Array .........................................................................................................................................................34

, ERV5000–10000(i/e) and HRV3000–10000(i/e) Start-up Form and Checklist .....................82

Manufacturer reserves the right to discontinue or change speciﬁcations or designs without notice or obligation.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 3

Nomenclature

1. TYPE OF HE

season and chilled water in cooling season

2. NUMBER OF AIRSTREAMS

3. SUPP

Rounded to the nearest thousand

4. INDICA

5. TYPE OF SUPPL TYPE OF EXHAUST

6. TYPE OF HEA

HGxxxx

DGxxxx

EnergyPack

Nomenclature (1,000–300,000+ cfm)

2 3 4 5 6 7 8 9

W – Wheel - total enthalpy

Ws – Wheel - sensible only

Pe – Plate - enthalpy (HM core)

Pa – Plate - AlphaFlowSM configuration, sensible only

H – Heat pipe heat exchanger U – U-shaped heat pipe A – No energy recovery device

B – DWDI backward inclined, or flat blade

W – FANWALL TECHNOLOGY

HW – Hot water coil

SC – Steam coil

yTxxxx – Gas-fired serpentine heaters

yRxxxx – Indirect gas-fired duct heaters

ECxxx – Electric duct heater (xxx = heating capacity)

HG – Hot gas reheat coil (condensing unit supplied by others)

IGxxxx – Indirect gas-fired heaters (xxxx = input heating capacity)

X – No heating

Illustrations cover the general appearance of Venmar CES products at the time of publication and Venmar CES reserves the right to make changes in design and construction at any time without notice.

™® The following are trademarks or registered trademarks of their respective companies: EnergyPack from Venmar CES Inc. and FANWALL from Huntair, Inc.

CES Group, LLC d/b/a Venmar CES furnishes equipment pursuant to its then-current Terms and Conditions of Sale and Limited Warranty, copies of which can be found under the Terms & Conditions of Sale and Warranty link at www.ces-group.com. Extended warranties, if any, shall be as offered and acknowledged in writing by Venmar CES.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

AT OR ENERGY RECOVERY DEVICE

P – Plate - sensible only

(polypropylene or aluminum)

(make-up or air handling units)

LY CFM

TES UNIT INSTALLATION

e – Unit installed outdoors

i – Unit installed indoors

Y FAN/

F – DWDI forward curved fan

P – SWSI plenum fan (backward inclined airfoil)

P – No fan

(y = # of furnace sections; xxxx = heating capacity)

– Hot gas reheat coil (condensing unit supplied by Venmar CES; xxxx = heating capacity)

– Direct fired gas burner (xxxx = input heating capacity)

FAN

TING

9. EXTERIOR FINISH

P – Painted finish (standard for exterior units) C – Corrosion resistant paint G – Galvanized metal - unpainted (standard for interior units)

8. TYPE OF HEATING/COOLING

HWCW – Hydronic coil for hot water in heating

HPxxxy – Dx coil with heat pump (xxx = cooling capacity; y = # of scroll compressors) RL – Runaround loop X – No heating/cooling

7. TYPE OF COOLING

CW – Chilled water coil Dx – Dx coil (condensing unit supplied by others) CSxxxy – Dx coil with air cooled condensing unit (xxx = cooling capacity; y = # of scroll compressors) CTxxxy – Dx coil with air cooled condensing unit (xxx = cooling capacity; y = # of scroll compressors in tandem) Cxxxy – Dx coil with air cooled condensing unit (xxx = cooling capacity; y = # of semi-hermetic compressors) EV – Evaporative cooling section X – No cooling

Page 4

1. FROST CONTROL

D E V N

3. SENSOR CONT

D W B

9. EXHAUST DISCHARGE

E T D

4. EXTERNAL FINISH

S G C

7. EXTERNAL DISCONNECT

F N X

8. OUTSIDE AIR INT

E T S B

5. OUTSIDE AIR DAMPE

1 2 3

6. EXHAUST AIR DAMPER

1 2 3

2. VO

B C D E F G N O – 230 V P Q – 575 V

10. SUPP

E T D

11. RETURN AI

E T B

Note:

1 2 3 4 5 6 7 8 9 10 15 hp motor is not available with this voltage option (*ERV10000i only).

5 96 7 81 2 3 4 10 13 14 15 16 17 18 1911 12

ERV5000–ERV10000 Indoor Nomenclature (4,000–10,000)

– Recirc defrost – Exhaust only – VSD frost prevention – Non-defrost

LTAGE/SPEED

– 208 VAC/1/60 – one-speed – 230 VAC/1/60 – one-speed – 208 VAC/3/60 – one-speed – 230 VAC/3/60 – one-speed – 460 VAC/3/60 – one-speed – 575 VAC/3/60 – one-speed – 208 VAC/3/60 – VFD

– 460 VAC/3/60 – VFD

– Dirty filter contacts – Wheel rotation sensor – Dirty filter contacts and

wheel rotation sensor

– No contacts, no sensor

– Standard galvanized package – Grey enamel paint finish – Corrosion resistant exterior paint finish

– Non-insulated spring return (low leak) – Insulated spring return (low leak) – No damper

– Fused disconnect switch – Non-fused disconnect switch – No disconnect switch

– End outside air intake – Top outside air intake – Side outside air intake – Bottom outside air intake

– End exhaust discharge – Top exhaust discharge – Down exhaust discharge

LY DISCHARGE

– End supply discharge – Top supply discharge – Down supply discharge

– End return air – Top return air – Bottom return air

When ordering frost control, you must order outside air and exhaust air dampers. VFD motors are not available with this frost control option. Outside air damper recommended. VFD motors are not available with this frost control option. No dampers required. All VFD options include one controller per motor. All VFD options for 575 VAC/3/60 include a line reactor. You must order an MEF supply filter when ordering HEF supply filtration. Fused/non-fused disconnect is factory installed. Electric heat is not available with single-phase motor options. Electric heat to be used in re-heat position only (not for frost control).

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

AC/3/60 – VFD

ACTS

AKE

8/10*

4/5

19. COIL ARRANGEMENT

H – Heating, cooling, access section C – Cooling, heating, access section S – Heating, cooling, no access section X – No access section (one coil or no coils)

18. COOLING

C – Chilled water (5 row) W – Chilled water (6 row) D – Dx cooling (5 row, 1 circuit) F – Dx cooling (6 row, 2 circuits) X – No cooling

17. HEATING

ERV5000i–10000i

H – Hot water (1 row) J – Hot water (2 row) S – Steam heat (1 row) G – Hot gas re-heat (2 row) X – No heat

ERV5000i

D – Electric heat (25 kW) E – Electric heat (43 kW) F – Electric heat (78 kW)

8/9

ERV6500i

D – Electric heat (35 kW) E – Electric heat (55 kW) F – Electric heat (100 kW)

ERV8000i

D – Electric heat (42 kW) E – Electric heat (71 kW) F – Electric heat (128 kW)

8/9

ERV10000i

D – Electric heat (54 kW) E – Electric heat (91 kW) F – Electric heat (164 kW)

8/9

16. PURGE SECTION

P – Purge section X – No purge section

15. BLOWER ISOLATION

R – Rubber in shear pads isolation S – Spring blower isolation

14. FREE COOLING

E – Free cooling (enthalpy controller) D – Free cooling (dry bulb) X – No free cooling

13. HEF FILTRATION

H – High efficiency supply filter (4” 80–85% MERV 14)

X – No HEF filtration

12. MEF FILTRATION

S – MEF supply filter

E – MEF exhaust filter B – MEF supply and exhaust filters X – No MEF filtration

Page 5

1. FROST CONTROL

D E V N

3. SENSOR CONT

D W B

9. SUPP

D E

4. EXTERNAL FINISH

S G C

7. EXTERNAL DISCONNECT

F N X

8. HOODS

H X

5. OUTSIDE AIR DAMPE

1 2 3

6. EXHAUST AIR DAMPER

1 2 3 4

2. VO

B C D E F G N O – 230 V P Q – 575 V

– Heating, cooling, no access section

10. RETURN AI

B E

11. MEF FIL

S E B X

Note:

1 2 3 4 5 6 7 8 9 10 11 15 hp motor is not available with the voltage option (*ERV10000e only).

5 96 7 81 2 3 4 10 13 14 15 16 17 18 1911 12

ERV5000–ERV10000 Outdoor Nomenclature (4,000–10,000)

– Recirc defrost – Exhaust only – VSD frost prevention – Non-defrost

LTAGE/SPEED

– 460 VAC/3/60 – VFD

– Dirty filter contacts – Wheel rotation sensor – Dirty filter contacts and

wheel rotation sensor

– No contacts, no sensor

– Standard galvanized package – Grey enamel paint finish – Corrosion resistant exterior paint finish

– Non-insulated spring return (low leak) – Insulated spring return (low leak) – No damper

– Non-insulated spring return (low leak) – Insulated spring return (low leak) – Gravity backdraft damper (low leak) – No damper

– Fused disconnect switch – Non-fused disconnect switch – No disconnect switch

– Intake/exhaust hoods – No hoods

LY DISCHARGE

– Down supply discharge – End supply discharge

– Bottom return air – End return air

– MEF supply filter – MEF exhaust filter – MEF supply and exhaust filters – No MEF filtration

When ordering frost control, you must order outside air and exhaust air dampers. VFD motors are not available with this frost control option. Outside air damper recommended. VFD motors are not available with this frost control option. No dampers required. Must order hoods when ordering dampers. All VFD options include one controller per motor. All VFD options for 575 VAC/3/60 include a line reactor. You must order an MEF supply filter when ordering HEF supply filtration. Fused/non-fused disconnect is factory installed. Electric heat is not available with single-phase motor options. Electric heat to be used in reheat position only (not for frost control).

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

AC/3/60 – VFD

ACTS

TRATION

9/11*

5/6

19. ROOFCURB

R – Insulated roofcurb X – No roofcurb

18. COIL ARRANGEMENT

H – Heating, cooling, access section C – Cooling, heating, access section S X – No access section (one coil or no coils)

17. COOLING

C – Chilled water (5 row) W – Chilled water (6 row) D – Dx cooling (5 row, 1 circuit) F – Dx cooling (6 row, 2 circuits) X – No cooling

16. HEATING

ERV5000e–10000e

H – Hot water (1 row) J – Hot water (2 row) S – Steam heat (1 row) G – Hot gas re-heat (2 row) X – No heat

ERV5000e

D – Electric heat (25 kW) E – Electric heat (43 kW) F – Electric heat (78 kW)

9/10

ERV6500e

D – Electric heat (35 kW) E – Electric heat (55 kW) F – Electric heat (100 kW)

ERV8000e

D – Electric heat (42 kW) E – Electric heat (71 kW) F – Electric heat (128 kW)

9/10

ERV10000e

D – Electric heat (54 kW) E – Electric heat (91 kW) F – Electric heat (164 kW)

9/10

15. PURGE SECTION

P – Purge section X – No purge section

14. BLOWER ISOLATION

R – Rubber in shear pads isolation S – Spring blower isolation

13. FREE COOLING

E – Free cooling (enthalpy controller) D – Free cooling (dry bulb) X – No free cooling

12. HEF FILTRATION

H – High efficiency supply filter (4” 80–85% MERV 14)

X – No HEF filtration

Page 6

1. FROST CONTROL

D E F T N

3. ENERGY RECOVER

P A H

9. EXTERNAL DISCONNECT

F N X

4. INTERNAL PROTECTION

1 2 3

7. OUTSIDE AIR DAMPER

1 2 3

8. EXHAUST AIR DAMPER

1 2 3

5. SENSOR CONT

D X

6. EXTERNAL FINISH

S G C

2. VO

B C D E F G N O – 230 V P Q – 575 V

10. OUTSIDE AIR INT

E T

11. EXHAUST DISCHARGE

E T

Note:

2 3 4 5

6 7 8 9 10

11 Traversing defrost is not available with the HM core option.

5 96 7 81 2 3 4 16 17 1810 11 12 13 14 15

HRV3000–HRV10000 Indoor Nomenclature (2,500–11,500 cfm)

– Recirc defrost – Exhaust only – Face and bypass – Traversing defrost – Non-defrost

LTAGE/SPEED

– 460 VAC/3/60 – VFD

– Poly core – Aluminum core – HM core

– 2” insulation, double wall – Corrosion resistant interior (heresite) – Pool application package

– Dirty filter contacts – No contacts

– Standard galvanized package – Grey enamel paint finish – Corrosion resistant exterior

– Non-insulated spring return (low leak) – Insulated spring return (low leak) – No damper

– Fused disconnect switch – Non-fused disconnect switch – No disconnect switch

– End outside air intake – Top outside air intake

– End exhaust discharge – Top exhaust discharge

When ordering frost control, you must order outside air and exhaust air dampers. Outside air damper recommended. And/or free cooling (c/w dampers and actuator). VFD motors are not available with this frost control option. No dampers required. Non-defrost is only available if the outside air temperature is greater than 10ºF [−17ºC]. Electric heat is not available with single-phase motor options. 15 hp motor is not available with this voltage option. (*HRV10000i only) All VFD options include one controller per motor. This option includes a line reactor. Traversing defrost may not be suitable under all thermal conditions with a polypropylene heat exchanger. Consult the factory.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

1/4

2/4

AC/3/60 – VFD

ACTS

AKE

6/7*

8/9

12/13/14

18. COIL ARRANGEMENT

H – Heating, cooling, access section C – Cooling, heating, access section S – Heating, cooling, no access section X – No access section (one coil or no coils)

17. COOLING

C – Chilled water (5 row) W – Chilled water (6 row) D – Dx cooling (5 row, 1 circuit) F – Dx cooling (6 row, 2 circuits) X – No cooling

16. HEATING

HRV3000i–10000i

H – Hot water (1 row) S – Steam heat (1 row) J – Hot water (2 row) X – No heat

HRV3000i

D – Electric heat (15 kW) E – Electric heat (27 kW) F – Electric heat (49 kW)

6/16

HRV5000i

D – Electric heat (25 kW)

E – Electric heat (43 kW)

F – Electric heat (78 kW)

HRV6500i

D – Electric heat (35 kW) E – Electric heat (55 kW) F – Electric heat (100 kW)

6/16

HRV8000i

D – Electric heat (42 kW) E – Electric heat (71 kW) F – Electric heat (128 kW)

HRV10000i

D – Electric heat (54 kW) E – Electric heat (91 kW) F – Electric heat (164 kW)

6/16

15. BLOWER ISOLATION

R – Rubber in shear pads isolation S – Spring blower isolation

14. FILTRATION

S – Standard filtration (2” 25–30% MERV 8) H – High efficiency filtration (4” 80–85% MERV 14)

13. RETURN AIR

E – End return air B – Bottom return air

12. SUPPLY DISCHARGE

E – End supply discharge D – Down supply discharge

12 The ‘Pool application package’ requires the following nomenclature options also be selected: ‘F – Face and bypass’ (Frost Control), ‘P – Poly core’ (Energy Recovery), ‘2 – Insulated spring return (low leak)’ (Outside Air Damper) and ‘2 – Insulated spring return (low leak)’ (Exhaust Air Damper). 13 The ‘Pool application package’ includes: corrosion resistant (heresite) internal unit protection, epoxy coating on the exhaust air fan, TEFC exhaust air fan motor, liquid tight conduit on all high voltage wiring, urethane insulation throughout (including insulated middle partition), condensate drain pan at exhaust air leaving station. 14 It is recommended that supply and return dampers be installed in the ductwork. These dampers shall close when the unit is not in operation. 15 Fused/non-fused disconnect switch is factory installed. 16 Electric heat to be used in re-heat position only (not for frost control).

Page 7

1. FROST CONTROL

D E F T N

3. ENERGY RECOVER

P A H

9. EXTERNAL DISCONNECT

F N X

4. INTERNAL PROTECTION

1 2 3

7. OUTSIDE AIR DAMPE

1 2 3

8. EXHAUST AIR DAMPER

1 2 3

5. SENSOR CONT

D X

6. EXTERNAL FINISH

S G C

2. VO

B C D E F G N O – 230 V P Q – 575 V

10. HOODS

H X

11. SUPP

E D

Note:

2 3 4 5

6 7 8 9 10

11 Traversing defrost is not available with the HM core option.

HRV3000–HRV10000 Outdoor Nomenclature (2,500–11,500 cfm)

5 96 7 81 2 3 4 16 17 1810 11 12 13 14 15

– Recirc defrost – Exhaust only – Face and bypass – Traversing defrost – Non-defrost

LTAGE/SPEED

– 460 VAC/3/60 – VFD

– Poly core – Aluminum core – HM core

– 2” insulation, double wall – Corrosion resistant interior (heresite) – Pool application package

– Dirty filter contacts – No contacts

– Standard galvanized package – Grey enamel paint finish – Corrosion resistant exterior

– Non-insulated spring return (low leak) – Insulated spring return (low leak) – No damper

– Fused disconnect switch – Non-fused disconnect switch – No disconnect switch

– Intake/exhaust hoods – No hoods

LY DISCHARGE

– End supply discharge – Down supply discharge

When ordering frost control, you must order outside air and exhaust air dampers. Outside air damper recommended. And/or free cooling (c/w dampers and actuator). VFD motors are not available with this frost control option. No dampers required. Non-defrost is only available if the outside air temperature is greater than 10ºF [−17ºC]. Electric heat is not available with single-phase motor options. 15 hp motor is not available with this voltage option. (*HRV10000i only.) All VFD options include one controller per motor. This option includes a line reactor. Traversing defrost may not be suitable under all thermal conditions with a polypropylene heat exchanger. Consult the factory.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

1/4

2/4

AC/3/60 – VFD

ACTS

6/7*

8/9

12/13/14

18. ROOFCURB

R – Insulated roofcurb X – No roofcurb

17. COIL ARRANGEMENT

H – Heating, cooling, access section C – Cooling, heating, access section S – Heating, cooling, no access section X – No access section (one coil or no coils)

16. COOLING

C – Chilled water (5 row) W – Chilled water (6 row) D – Dx cooling (5 row, 1 circuit) F – Dx cooling (6 row, 2 circuits) X - No cooling

15. HEATING

HRV3000e–10000e

H – Hot water (1 row) S – Steam heat (1 row) J – Hot water (2 row) X – No heat

HRV3000e

D – Electric heat (15 kW) E – Electric heat (27 kW) F – Electric heat (49 kW)

6/16

HRV5000e

D – Electric heat (25 kW) E – Electric heat (43 kW) F – Electric heat (78 kW)

HRV6500e

D – Electric heat (35 kW) E – Electric heat (55 kW) F – Electric heat (100 kW)

6/16

HRV8000e

D – Electric heat (42 kW) E – Electric heat (71 kW) F – Electric heat (128 kW)

HRV10000e

D – Electric heat (54 kW) E – Electric heat (91 kW) F – Electric heat (164 kW)

6/16

14. BLOWER ISOLATION

R – Rubber in shear pads isolation S – Spring blower isolation

13. FILTRATION

S – Standard filtration (2” 25–30% MERV 8) H – High efficiency filtration (4” 80–85% MERV 14)

12. RETURN AIR

E – End return air B – Bottom return air

Page 8

Safety Considerations

Warning, Caution and Important notes appear throughout this manual in speciﬁc and appropriate locations to alert Installation Contractors, Maintenance or Service Personnel of potential safety hazards, possible equipment damage or to alert personnel of special procedures or instructions that must be followed as outlined below.

WARNING

Identiﬁes an instruction which, if not followed, might cause serious personal injuries including possibility of death.

CAUTION

Identiﬁes an instruction which, if not followed, might severely damage the unit, its components, the assembly or ﬁnal installation.

IMPORTANT

Indicates supplementary information needed to fully complete an instruction or installation.

General Information

Hazards may exist within this equipment because it contains electrical and powerful moving components. Only qualiﬁed service personnel should install or service this equipment. Untrained personnel can perform basic maintenance such as maintaining ﬁlters. Observe precautions marked in literature and on labels attached to the unit. Follow all safety codes.

WARNING

Disconnect the main power switch to the unit before performing service or maintenance. Electric shock can cause personal injury or death.

This manual is designed to provide general information on the common operation of all standard and optional components that may have been installed in the unit. Note that some sections of this manual may not apply to your unit. This manual has been designed for a general purpose and describes all options offered by Venmar CES that could be included in the unit. Consult the manual from the component manufacturer if more detailed technical information about a speciﬁc component is required.

Recommended Spare Parts

Spare parts should be ordered at the time the installation is accepted by the owner. Spare parts will reduce the down time in the event of a failure. The list of spare parts outlined below is considered minimal. Installation in remote locations or when the operation of heating equipment is essential may require more spare parts than listed. Please contact the service department at Venmar CES for recommendations.

All documentation that was speciﬁcally designed for your unit has been included in the pocket of the control panel, including (and if applicable):

• Mechanical drawings

• Unit nomenclature

• Electrical schematics

• Sequence of control

• Variable Frequency Drive (VFD) manual and CD (when supplied)

• DDC controller documentation (when supplied)

User’s manual Communication protocol documentation Keypad documentation

Minimum spare parts include:

• Two sets of fuses

• One matching set of fan belts

• One set of ﬁlters

• One burner control relay module, ﬂame signal ampliﬁer and purge card (optional)

• One ﬂame sensor (optional)

• One spark igniter (optional)

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 9

Unit Inspection on Arrival

Inspect the equipment exterior and interior for any damage that may have occurred during unit shipment and for shipped loose parts. Ensure there is no damage to any protruding exterior components such as door handles, disconnect switch handle, etc. or to internal components such as fans, motors, heat exchanger, dampers and drains.

Unit Application Limitations

CAUTION

Venmar CES equipment is not designed to be used for temporary heating, cooling and/or ventilation during construction.

Using Venmar CES units for temporary ventilation during construction is subject to the unit warranty terms and should be reviewed carefully before proceeding, as this may void the standard warranty conditions.

Installation

Unit Location Requirements

File a claim with the shipping company if the unit is damaged. Check the packing slip against all items received. If any items are missing sign the carrier’s bill of landing with the notation “Shipment Received Less Item #_____.” Contact the factory immediately if damage is found. No return shipment will be accepted without authorization.

Fine dust, larger particulate matter, solvents, varnishes and other chemicals may cause ﬁlter clogging and elevated cabinet pressures, higher power consumption and possible irreparable damage to the desiccant material of the energy recovery device, which could reduce energy recovery performance and also reduce the heat transfer effectiveness of other components. Potential damages include, but are not limited to, these examples.

Consult local building codes and electrical codes for special installation requirements and note additional requirements listed in this manual. In choosing the installation location of the unit, consider the following factors:

• The unit should be installed to allow easy access for maintenance and for systems operation.

• Clearance around the unit should be a minimum of 39” [1,000 mm] and 48” [1,219 mm] around the condenser section to allow easy access for maintenance and for system operation. For clearances to remove component, consult factory.

• Locate the unit in an area requiring the least amount of ductwork and direction changes to allow optimum performance, to reduce pressure loss and to use less electricity to achieve proper ventilation. Ductwork must be in accordance with ducting mechanical rules to prevent sound issues and system effects.

• The fresh air intake hood must be positioned away from sources of contamination such as other HVAC unit exhaust outlets or vents, hot chimneys or kitchen exhaust vents.

• Fresh air intake must also be positioned in a direction opposite to that of prevailing winds and clear of any obstruction to prevent turbulence buildup to reduce entry of snow or rain.

• The unit should be mounted on a level foundation to allow condensation to ﬂow into internal drains.

The foundation must provide adequate continuous support to the full perimeter of the base and all cross members requiring support to minimize deﬂection of the unit base frame to not more than 1/16” [1.6 mm] over the entire length and width. In addition to these recommendations, a Structural Engineer must be involved to properly size supporting structural elements.

• When mounting the unit indoors, if drain connections are required, mount the unit on a housekeeping pad of sufﬁcient height to allow for drain trap height and condensate lines to slope toward the building drain, install condensate pumps to reduce height of housekeeping pads or drill holes in the concrete pad or mechanical room ﬂoor for sufﬁcient trap height.

• When mounting the unit on a roofcurb check the height from the ﬁnished roof to the bottom of the intake hood. Consult with local authorities or your building code for minimal intake hood height for the water-tight height from and above the ﬁnished roof, and in snow prone areas, the buildup of snow, to determine the height of the roofcurb. Venmar CES optional roofcurbs measure 18” [457 mm] in height. If additional height is required from the ﬁnished roof to the top of the roofcurb, to the bottom of the intake hood or if other than level, custom height roofcurbs must be ordered.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 10

Roofcurbs Supplied by Venmar CES (External Applications Only)

Roofcurbs supplied by Venmar CES should be mounted as follows:

• The roofcurb is shipped knocked-down with assembly hardware and instructions provided. The roofcurb must be ﬁeld erected, assembled and set in place by the Installing Contractor (see Appendix A).

• Roofcurb dimensions are submitted with the unit mechanical drawings which can also be found in the unit control panel pocket or by calling Technical Support personnel from the Venmar CES factory.

• The cross members must be positioned as per the roofcurb drawing to properly support the unit.

• The building structure must provide continuous structural support under the full perimeter of the roofcurb and under all cross members.

• After the roofcurb has been assembled, ensure that the curb dimensions suit the unit for which it is designated and also ensure that the structural supports for the roofcurb are correct.

• Ensure that the assembled curb is square, plumb and level to within 1/16” [1.6 mm] over the entire length. The roofcurb must be shimmed to the building structure as required to provide continuous support under its full perimeter and under all its cross members.

• The roofcurb must be fastened to the building structure.

Continuous ½” bead ADBOND 1465 acoustical butyl sealant

Figure 1: Continuous ½” [13 mm] bead of ADBOND 1465 acoustical butyl sealant or equivalent applied to top perimeter of roofcurb and ½” x 1½” [13 x 38 mm] gasket with adhesive strip applied to the bottom duct opening connections just prior to unit installation.

• The Installing Contractor is responsible for making the curb water-tight by caulking all roofcurb joints.

• See Appendix A for assembly instructions for standard design curbs or with optional wood nailer.

IMPORTANT

The following items must be completed prior to setting the unit on the roofcurb.

• The roofcurb rooﬁng must be completed including insulation, cant strip, ﬂashing and counter-ﬂashing.

• Vertical ductwork supplied by Sheet Metal Contractor must be attached to the roofcurb cross members and building structure, not to the unit. See Field

Fabricated Ductwork for suggested ductwork at-

tachment.

• If there is no building roof access underneath the unit, and drain or piping connections must be made (in the rooﬁng), it is recommended to do so before unit installation using the appropriate materials provided by the Installing Contractor.

• Use the ADBOND 1465 acoustical butyl sealant supplied with the unit and apply a continuous ½” [13 mm] bead to the top perimeter of the roofcurb for a positive air and water-tight seal and to ease section movement when pulling modules together (if applicable). The ADBOND 1465 acoustical butyl sealant remains indeﬁnitely pliable and sticky and should only be applied just prior to unit installation to avoid smudging.

• Use the ½” x 1½” [13 x 38 mm] polyvinyl gasket with adhesive strip supplied with the unit and apply it on top of the perimeter of the duct opening connections.

IMPORTANT

The ADBOND 1465 acoustical butyl sealant between the unit and the roofcurb is critical for a positive air and watertight seal. If improperly applied this can result in air and water leakage and poor unit performance (see Figure 1).

Roofcurbs Supplied by Others

Roofcurbs supplied by others must be designed with the same dimensions, cross member arrangement and location as per Venmar CES roofcurb drawings and must be designed to evenly withstand perimeter and cross section static loads.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

IMPORTANT

Venmar CES is not liable for any damages, costs or other issues arising from roofcurbs supplied by others.

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Rigging, Lifting and Assembling

IMPORTANT

• Carefully read all the instructions contained herein. Before proceeding with any work, correlate these instructions with the information provided on the curb and equipment shop drawing for the speciﬁc project.

• These instructions outline the suggested method of rigging, lifting and installing a Venmar CES unit. All local codes and ﬁre regulations must be veriﬁed and adhered to by the Installing Contractor.

• Before assembling, hoisting or setting any pieces of the supporting curbs or units, verify that the proper unit is being directed to the correct location, as designated by the architectural and engineering design drawings.

• Safety ﬁrst: ensure that all safety practices recommended by local safety associations are continuously in use.

• If any questions arise during the installation procedure, please contact the factory.

• The Installing Contractor is responsible for the unit being air and water-tight at the joints between sections and between the roofcurb and the unit.

• All holes that have been made by the Installing or Electrical Contractor after receiving and installing the unit must be well sealed to prevent air and/or water inﬁltration.

Rigging, Lifting and Assembling Equipment

All rigging equipment and labor (as applicable) is provided by the Installing Contractor as detailed below. It is highly recommended that extra quantities of all items listed be on hand. The rigging procedure and/or equipment used to lift the unit may differ depending on the physical dimensions of the unit, its location, the jobsite, the Installing Contractor and Crane Operator preferences.

• Lifting crane of the appropriate capacity

• Adjustable spreader bars

• Cables (cables, chains or straps)

• Curb ﬂashing (when required—based on rooﬁng construction)

• All tools required to pull the sections together (chains, chain blocks, chain type come alongs, etc.)

• All construction equipment and labor required to complete the work according to local codes

• Condensate and/or P-trap piping hardware

• All tools and materials required for level unit installation

• ½” [13 mm] wood shims required to set the gap between the unit base frame and the curb

Installation and Assembly Materials

All materials for sealing the unit to the top of a factory supplied roofcurb, for assembling a multi-sectional unit as detailed below and per the instructions that follow are

supplied by Venmar CES and located inside one (or more) of the unit sections, where this (yellow) label, as shown below, is applied on the door.

IMPORTANT

• Installation and assembly materials are in this section.

• Before setting unit on a roofcurb or structural support, read and follow the Rigging, Lifting and Assembling Instructions in the Installation, Operation and Maintenance Instructions Manual.

For Single Section Units

• ADBOND 1465 acoustical butyl sealant or equivalent (applied to top perimeter of curb just prior to unit installation).

• Polyvinyl gasket with adhesive strip (½” x 1½” [13 x 38 mm] x required length) applied on duct opening connections.

For Multi-section (Modular) Units

• ADBOND 1465 acoustical butyl sealant or equivalent (applied to top perimeter of curb or to the top perimeter joint of a horizontally split indoor unit lower section just prior to unit installation). The use of ADBOND 1465 acoustical butyl sealant or equivalent is required to create a proper seal to minimize the risk of water inﬁltration and ease section movement when pulling modules together. Do not use the butyl sealer on the exterior split section joints as it remains pliable, sticky and should it become smeared is difﬁcult to clean.

• Polyvinyl gasket with adhesive strip (½” x 1½” [13 x 38 mm] x required length) applied between unit sections (for split section joints and duct opening connections).

• 3/8” x 4” Grade 5 full thread zinc plated bolts, with two washers and one nut each (to secure sections together).

• Adseal 1800 series (from Adchem Adhesives) clear silicone based sealant or equivalent (for side joint and top joint).

• Roof seam ends made of metal with applied gasket.

• Roof joint caps x required length.

• Self-drilling 5/16 hex head #12-14 x 1” zinc plated screws with rubber washer (for roof caps).

Rigging, Lifting and Assembling Instructions

Depending on size, the unit or unit sections of a multisection (modular) unit will arrive at the jobsite on a standard ﬂatbed or special low bed trailer. Each unit or unit section is identiﬁed with labels, as per the mechanical drawings. At ground level, ensure that any crating used for shipping purposes is removed if there is a possibility that it will interfere with the placing or assembling of the unit or unit sections on the roofcurb, structural steel or housekeeping pad.

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Page 12

IMPORTANT

See Detail A

For multi-section (modular) units, make certain to always rig, lift and install an end section with bottom duct connection ﬁrst.

Unit or unit sections shall be lifted by cables attached to all the lifting lugs. Consult the mechanical drawings located in the pocket of the control panel for the number of lifting lugs, number of sections and unit weight. For multisection (modular) unit check for additional lugs located between split sections. Lifting lugs are factory bolted to the unit or unit section base.

CAUTION

All lifting lugs provided must be used when rigging units or unit sections. Rigging and lifting unit or unit sections without using all lifting lugs provided will compromise the structural integrity of the unit or unit section. Never lift, rig or ceiling suspend from the top of the unit or unit sections. Using a forklift or similar device for moving, lifting or rigging unit or unit sections is prohibited.

When lifting the unit or unit sections, use adjustable spreader bars, pulleys, cables (straps or chains) in order to properly distribute the load, applying an even vertical lifting force only at all the lifting lugs to prevent structural damage to the unit or unit section or prevent cables from rubbing against the cabinet (see Figure 2). Provide additional blocking and coverings (as required) to prevent damage to the unit ﬁnish and/or components. The adjustable spreader bars are required to maintain a clearance between the cables and the unit or unit section of at least 12” [305 mm] beyond the sides. Venmar CES will not be responsible for any damage caused to the unit casing during the lifting process. Main areas where damage may occur are: electrical panels, ﬁlter gauges, rain gutters, hoods, rooﬁng corners, door handles and paint ﬁnish. The lifting point must be at the center of gravity to ensure that the unit or unit section is level during hoisting and prior to setting. When commencing to hoist, take up the slack in the hoisting cables slowly and gradually increase the cable tension until the full unit or unit section weight is suspended. Avoid sudden, jerking movements. Do not permit the unit or unit section to be suspended by the lifting lugs for an extended period of time. Once the unit or unit section leaves the trailer ensure it is level at all times.

Adjustable spreader bars (typ.)

Pulleys (typ.)

Detail A

Use clevis and clevis pin to attach cable to lifting lugs.

12” 12”

Pulleys

Adjustable spreader bars

12” min.

Figure 2: Use adjustable spreader bars, pulleys and cables attached to all lifting lugs to apply an even lifting force.

1. Set the unit, unit end or a bottom half of a horizontal split unit end section with bottom duct connection of a multi-section (modular) unit in place ﬁrst.

IMPORTANT

The unit or a unit end section with bottom duct connection of a multi-section (modular) unit must be set onto the curb ﬁrst such that a gap of ½” [13 mm] is left between the curb and the unit base frame on all outer sides, as shown in Figure 3. Use ½” [13 mm] wood shims to set the gap as shown in Figure 4. This is important, as it will later on prevent the ﬁrst section from sliding on the curb towards the next sections, when pulling the multisection (modular) unit together and align the duct connection of the unit with the curb. Figure 4 shows a curb mounted unit installation where the curb sits inside the unit perimeter base and the unit base overhangs the curb to prevent water entry.

For structural steel or pad mounting, if the dimensions of the support is larger than the curb, then the end section base must be positioned so the duct connection lines up properly and then fastened to the structural steel or pad to prevent the end section from moving when pulling sections together. Fastening method must be determined by the Installing Contractor. The lifting lugs on the outside perimeter may be removed with bolts and internal nuts used to fasten unit to structural steel or pad. All bolts should be returned and sealed to prevent leakage.

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Figure 3: Set unit or an end section with bottom duct connection of a multi-section (modular) unit ﬁrst using ½” [13 mm] wood shims on outer sides to properly position and to prevent movement when pulling sections together.

Temporary ½” wood shim (supplied by contractor)

b. Set the upper or top section over the lower sec-

tion lining up the bolt holes in the perimeter ﬂanges for a horizontally split indoor unit or section (see Figure 5b).

Figure 5b: Set the upper or top section over the lower section lining up all the bolt holes in the perimeter ﬂanges.

c. Use the 3/8” x 4” bolts, nuts and washers to secure

the upper or top section to the lower or bottom section as shown in Figure 5c. Gradually tighten all bolts to apply an even load along the external joints (not at any point).

Figure 4: Use ½” [13 mm] wood shims on outer sides to properly position and/or to prevent movement when pulling multi-section (modular) units together.

Assembling a Multi-section (Modular) Unit

Special attention must be taken to ensure that a multisection (modular) unit has an air and water-tight seal at every section split. Follow the next set of instructions for assembling a multi-section (modular) unit.

2. For a horizontally split indoor unit or section: a. Apply a continuous ½” [13 mm] bead of ADBOND

1465 acoustical butyl sealant on the top perimeter of the lower or bottom section 1½” [38.1 mm] from the outer edge as shown in Figure 5a.

½” [13 mm] bead of ADBOND 1465 acoustical butyl sealant

1½”

Figure 5c: Use the 3/8” x 4” bolts ,nuts and washers and gradually tighten to apply even load to secure sections.

CAUTION

Do not over tighten joint bolts as this may cause the bottom section frame to warp and break the air-tight seal.

3. Remove the yellow lifting lugs located on the section joint (if any) once the ﬁrst section is set in place.

IMPORTANT

Yellow lifting lugs located on the section joint (if any) must be removed once the ﬁrst section is set in place to allow the next section to be pulled to the ﬁrst.

1½”

Figure 5a: Apply a continuous ½” bead of butyl sealer on the top perimeter of the lower or bottom section.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Detail at A

4. Set the second section approximately 6” [152 mm] from the ﬁrst section (see Figure 6). If second section has a horizontal split, the top section must be installed as

Page 14

per procedure #2 above before proceeding. Use ½”

[13 mm] wood shims on outer sides to properly position and to prevent movement when pulling multisection (modular) unit together when mounted on a roofcurb. Remove the yellow lifting lugs located on the section joints (if any) from the second section to allow sections to be pulled together.

6” max.

Figure 6: Set the next section approximately 6” [152 mm] from the ﬁrst section.

5. Corner reinforcement brackets or angle bars may have been used to support multi-section (modular) unit walls during transportation, rigging and lifting at the split. The brackets shown in Figure 7 are for larger units. Simple angle bars are used for smaller units (not shown). The corner reinforcement brackets or angle bars are no longer required after rigging and lifting and must be removed.

IMPORTANT

After the corner reinforcement brackets or angle bars have been removed from the split section, set the screws along with the rubber washers that were holding the brackets or angle bars back in place for water-tightness.

7. Install the ½” x 1½” [13 x 38 mm] polyvinyl gasket with adhesive strip directly on one side of the split section perimeter frames and middle interior partitions as shown in Figure 8a through Figure 8e.

8a, 8c

8d, 8e

Figure 8: General gasket layout

IMPORTANT

Make sure to have full contact between strips wherever a discontinuity is present, for air and water-tightness.

½” x 1½” polyvinyl gasket

¼”

Figure 8a: Install a polyvinyl gasket strip on each vertical outside wall ¼” [6.4 mm] from the outside side edge from top to bottom of the side joint. When compressed, a small gap will remain which will allow the Adseal 1800 series silicone based sealant or equivalent to seal the vertical side edges (explained in Figure 11).

Top of frame

Figure 7: Corner reinforcement brackets or angle bars to be removed from the split section. Reset the screws with rubber washer in place for water-tightness.

6. Verify that these two sections are aligned square at the joint in all three directions.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Bottom of frame

Figure 8b: Install two horizontal polyvinyl gasket strips along the base frame, one at the top and one at the bottom of the base frame, between the two vertical side gasket strips so there is full contact between gasket strips for air and water-tightness.

Page 15

Figure 8c: Install one horizontal polyvinyl gasket strip along the top frame between the two vertical side gasket strips so there is full contact between gasket strips for air and water-tightness.

8. Use tools (chains, chain blocks, chain type come along, etc.) connected to the side lifting lugs (attached to the base) on both sides of the unit to pull the second or next section to the ﬁrst end section evenly until both sections are ¼” [6.4 mm] apart on the full joint perimeter as in Figure 9. Remove any exterior lifting lugs that interfere with the chains for pulling sections together. When joining sections together, always apply the pulling force to the lifting lugs attached to the unit structural base, never to the corner posts and pull uniformly from both sides of the unit section. The butyl sealer previously applied on the roofcurb top surface will allow the unit section to slide into position.

IMPORTANT

Unit sections must be drawn together using the lifting lugs attached to the unit structural base only.

CAUTION

Do not use the vertical side casing framing or bolt holes to pull sections together as this may cause the corner posts to warp and break their air and water-tight seal.

Middle internal partition(s)/divider(s)

Figure 8d: Where two or more internal air tunnels/corridors are present, install the gasket strips on the middle internal horizontal and/or vertical partition(s)/divider(s), between the perimeter gasket strips so there is full contact between gasket strips for air and water-tightness.

Figure 8e: Where a multi-sectional indoor unit with vertical and additional horizontal splits join, the middle internal horizontal partition will require three gaskets. One at the top of the bottom section and two at the bottom frame of the top section.

Displacement

Tools supplied by others

Figure 9: Use tools (chains, chain blocks, chain type come along, etc.) hooked to the unit lifting lugs attached to the structural base on both sides of the unit to pull the second or next section to the ﬁrst section evenly.

9. With the sections pulled together, use the 3/8” x 4” bolts, nuts and washers to secure the sections together along the sides as in Figure 10. Start at the bottom and gradually tighten all bolts to apply an even load along both sides and for indoor units along the top (not at one place) until sections or gasket is compressed within ¼” [6.4 mm].

CAUTION

Do not over tighten the side bolts as this may cause the corner posts to warp and break their air and water-tight seal.

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Figure 10: Secure the sections pulled together with bolts, nuts and washers. Do not over tighten.

10. After two sections are assembled, verify that the assembly is level and square. If an adjustment is required, make certain to address it immediately, not at the end of the ﬁnal assembly.

11. If multi-section unit has more than two sections, follow Steps 2 through 9 for each additional section, always pulling the next section from the ﬁrst end section.

12. Apply a generous bead of Adseal 1800 series clear silicone based sealant or equivalent to the exterior side frame joint seams sufﬁciently to completely cover the section split gasket and in such a way that the silicone bead meets with both frames as in Figure

11. The bead of clear silicone based sealant should ﬁll the ¼” gap, as shown in Figure 11.

Note: Cap should be on same j oint.

Figure 12a: Install the metal roof seam end with applied gasket by applying a 45° force to it until the neoprene is fully compressed. Lock into position with two self-drilling 5/16” hex head #12-14 x 1” screws with rubber washer until the rubber washer is compressed. Repeat for other end.

Figure 12b: Always install the roof joint cap(s) end with two sideby-side pre-punched holes on the lower side of the roof slope. Center and install the roof joint cap(s) with self-drilling 5/16” hex head #12-14 x 1” screws with integrated gasket until the gasket is compressed in all pre-punched holes.

¼” bead Adseal 1800 clear silicone based sealant

Figure 11: Apply a continuous bead of Adseal 1800 clear silicone based sealant or equivalent to the exterior side frame joints and for indoor units along the top frame joints.

13. Install the roof joint caps with self-drilling screws in all pre-punched holes for an air and water-tight seal as shown in Figure 12a and Figure 12b (for outdoor units only).

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

If unit is wider than 138” [3,505 mm], roof slope is

double pitched from center and two or more roof joint caps will be supplied (see Figure 12c).

Figure 12c: Install middle joint cap at each roof joint cap junction(s).

Page 17

14. All lifting lugs removed on the exterior of the base for pulling sections together must be returned or if not desired the bolts must be set back in place. Once removed, the bolts must be returned and sealed with clear silicone based sealant for water-tightness. All other lifting lugs from the unit base may be removed, if desired, or left in place. When removing lifting lugs on the exterior of the base, set the bolts back in place and seal with clear silicone based sealant for water-tightness.

15. Touch-up paint for scratches or marks to the external ﬁnish incurred during shipment or installation can be obtained in the fastest amount of time in bulk or spray cans from a local paint supplier by providing the universally recognized RAL code. To match the Venmar CES standard grey specify color RAL K7 Classic #RAL7001, two-component polyurethane paint with a gloss of 30+/−4.

Paint cans (11 ounces) matching the Venmar CES

grey can also be obtained in a slower amount of time

Hood Installation

by contacting the following paint suppliers listed below and providing the item number, item name and Vendor number below or through Venmar CES after sales service by: email to Tech Support at venmarservice@venmarces.com, fax 899-319-2612 or phone 1-866-4-VENMAR.

In Canada

Sunamco 360 Gleme Rue C.P 280 Daveluyville, Quebec G0Z 1C0 Phone: 1-866-815-4080 Contact: Audrey Mallhot

Item number: 500049624 Item name: Canette peinture grise RAL7001 Vendor number: VEN00002429

In USA

Using the universally recognized RAL code (RAL7001), Venmar CES Grey paint can be obtained from your local supplier.

If the intake or exhaust air hoods for the unit have been shipped separately, they are assembled and ﬁtted with lifting plates for hoisting into position and holes are prepunched into the hood ﬂanges for mounting. Apply a continuous length of 1/8” x 1” [3.2 x 25.4 mm] neoprene Soft Seal gasket with adhesive strips to the hood ﬂange perimeter and install with the 3/8” hex head #12–14 x 1” self-

Indoor Suspended Installation

To install indoor units that will be permanently suspended, the units must be set on structural steel beams that are supported by vertical rods. Venmar CES recommends beams under the full perimeter and all cross members requiring support. In addition to these recommendations, a Structural Engineer must be involved to properly size the supporting structural elements. Note that the locations of the beams shall be coordinated with the location of access doors to prevent any interference (see Figure 13). Single section unit shown; for multi-sectional unit suspension, consult factory.

drilling zinc plated screws supplied. Then apply a bead of Adseal 1800 clear silicone based sealant or equivalent to the outside perimeter of the hood ﬂange for a water-tight seal to the unit casing. If the hood lifting plate extension is not desired, remove hood lifting plates, turn 180° and screw back in place to ﬁll holes to maintain paint ﬁnish.

Anchor

40”

40” min.

Figure 13: Indoor suspended installation

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Field Fabricated Ductwork

On outdoor bottom vertical duct connections, support all ducts to the roofcurb and building structure. Do not sup-

port ductwork from the unit.

See Figure 14a for a curb mounted outdoor unit. Suggested methods of attaching ductwork to bottom of outdoor unit are as follows.

• Attach ½” x 1½” polyvinyl gasket with adhesive back to ductwork ﬂanges and fasten ductwork ﬂanges with self-drilling sheet metal screws to bottom frame of unit duct opening where access to bottom of unit is available once unit is installed. Ductwork must be supported by building structure.

• Field provide and install ductwork supports across perimeter curb frame and/or cross members level with top of perimeter curb, install ductwork plenums with top perimeter ﬂanges in supports and fasten with self-drilling sheet metal screws. Attach ½” x 1½” polyvinyl gasket to ductwork ﬂanges prior to setting unit on roofcurb.

• Field provide and install ductwork curb level with top of perimeter curb, install ductwork plenums in ductwork curb with top perimeter ﬂanges and fasten with self-drilling sheet metal screws. Attach ½” x 1½” polyvinyl gasket to ductwork ﬂanges prior to setting unit on roofcurb.

all duct connections to prevent air leakage and system performance problems. Ductwork must be supported by the building structure.

For bottom ductwork connections on pad or support steel mounted indoor units, if the pad is larger than the inside base frame of the unit, the bottom duct opening frame is 1” above the bottom base of the unit (see Figure 14b). If there is no access available to fasten ductwork ﬂanges with self-drilling sheet metal screws to the bottom frame of unit duct opening, the pad opening must match the ductwork opening and be raised by 1” to allow ﬂanges on ductwork plenums to seal to the bottom opening frame as described for outdoor units.

½” x 1½” polyvinyl gasket

1”

½” x 1½” polyvinyl gasket

Figure 14a: Bottom ﬁeld fabricated ductwork connection for outdoor curb mounted units

On horizontal or indoor vertical duct connections, make connections to the casing by applying Adseal 1800 silicone based sealant or equivalent around the connection and screwing ﬂanged ducts directly to the casing and/or ﬂange with self-drilling sheet metal screws. It is important to seal

Figure 14b: Bottom ﬁeld fabricated ductwork connection for indoor pad mounted units

For duct connection sizes, see the mechanical drawings. Insulate and weatherproof all external ductwork, joints and roof openings with counter-ﬂashing and mastic in accordance with applicable codes. Ductwork running through roof decks must comply with local ﬁre codes. Ducts passing through unconditioned spaces must be insulated and covered with a vapor barrier. Flexible connectors should be installed close to the unit in the duct leading to occupied spaces to minimize noise transmission.

The design of the ductwork immediately downstream of the gas-ﬁred furnace is critical for successful applications. Poorly designed ductwork can contribute to excessive temperature ﬂuctuations. Avoid splitting or branching of the ductwork immediately downstream or within ﬁve duct diameters from the discharge where temperature stratiﬁcations may exist.

The design of the ductwork immediately downstream of a double width forward curved or backward inclined fan is critical to the performance of the fan. The velocity proﬁle at the outlet of the fan is not uniform and an elbow located at or near the fan outlet will, therefore, develop

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 19

a pressure loss greater than its ”handbook” value and

must be included in the external static pressure calculations. Consult the AMCA Fan Application Manual publication 201 for recommendations and system static pressure losses.

The ventilation system should be designed according to maximum airﬂow needs. To minimize noise level and loss of pressure, ducts should be designed for a maximum air velocity of 1,200 feet per minute, keeping the direction and transition changes to a minimum. To further reduce noise transmission, line the ﬁrst 15 feet [4,572 mm] of duct with acoustic insulation. Elbows with a turning radius equal to or greater than one, or 90° elbows with turning vanes, should also be used.

Electrical Connections

When an Energy Recovery Ventilator (ERV) is installed in conjunction with a forced air system Air Handling Unit (AHU), the AHU and network of ducts are used to supply fresh air inside the building. In this type of system, the main fan of the AHU must be in continuous operation when the ERV is on. Supply air from the ERV should be introduced into the return duct of the AHU no less than 6 feet [1,829 mm] upstream from the AHU. The ERV return duct connection should be at least 2 feet [610 mm] upstream of the ERV supply air duct connection in the AHU return duct.

WARNING

When installed, the unit must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA70, and/or the Canadian Electrical Code CSA C22.1. Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. Failure to follow this warning could result in the Installer being liable for personal injury of others.

The unit is factory wired (unless otherwise speciﬁed) except for power connections, shipping split locations, shipped loose sensors/items or remote control options as indicated in the electrical schematics and sequence of control. The unit may or may not have an optional factory installed door interlocking disconnect in the control panel. If the unit control panel disconnect is not supplied, the Electrical Contractor must provide and install disconnect outside of the unit as per local electrical codes and run the power supply wiring to the control panel.

• For multi-section (modular) units, the Electrical Contractor must join the low and high voltage wiring between sections at the junction boxes or extend coiled wiring.

IMPORTANT

Wire nuts and electrical butt connectors (if required) must be supplied by the Electrical Contractor.

• Check nameplate for correct power supply requirements.

• See electrical schematics and sequence of control located in the control panel pocket for ﬁeld wiring of power connections, shipped loose sensors, items or

remote control interlocks. The Electrical Contractor must locate, install and wire sensors, items or remote control interlocks as per electrical schematics and sequence of control.

• Numbered terminals strips are included in the control panel for ease of connection and service.

• All ﬁeld wiring and components must comply with NEC and local requirements. In Canada, electrical connections must be in accordance with CSA C22.1 Canadian Electrical Code Part One.

• Install copper wiring of proper size to handle current load.

• The base unit control includes an external contact and is not equipped with a remote control panel. This contact is located in the unit control panel. The Installer must connect the external contact to a controller normally located in the building. This controller can be a humidistat, switch or timer, etc. Optional controls are 24 VAC.

• The remote control panel is optional and when included has numbered terminals matching the unit control panel terminals. Use wiring equal to AWG18 to connect like-numbered terminals.

• Mounting of ﬁeld provided components in the control panel is allowed as long as their space was considered during the submittal process. Non-considered electrical components are not allowed in the control panel. It is the responsibility of the Control Contractor to provide his own power source(s) for any ﬁeld added electrical components. The control panel mounted transformers are not rated for external components power supply unless otherwise listed on the electrical schematics.

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Page 20

Electrical Field Connections

CAUTION

Electrical components and contacts must be protected from damaging metal shavings before drilling holes into the control panel. Use liquid-tight connections through the control panel and unit casing eliminating any water and air penetration.

Shipped loose sensors, items or remote control wiring can be located next to the power feed cable provided it is inserted in shielded cable that will protect it from electromechanical interference. Ensure the power feed cable ground is securely connected to the terminals located in the control panel.

Electrical Contractor must provide wiring for controls that are supplied optionally and shipped loose or ﬁeld supplied. Mark the electrical schematic with the connections completed and leave them with the unit for start-up and service.

Coil, WSHP or Humidiﬁer Piping Connections

CAUTION

High voltage power lines, shipped loose sensors, items or remote control option ﬁeld wiring entry points may only be ﬁeld extended through the cabinet within designated areas. The unit cabinet and/or ﬂoor must be wisely penetrated in order to keep their integrity. Access openings in the ﬂoor can only be cut or drilled for piping and wiring (high and low voltage) in the designated rectangular areas within an upturned 1” [25.4 mm] ﬂange as provided during the submittal process and located on the mechanical drawings. Access openings must be sized, ﬁeld cut or drilled by the Installing Contractor within the rectangular ﬂanged area then sealed air and water-tight. If insulation was removed to create ﬂoor access openings, insulation must be put back in place to avoid condensation. Do not cut or drill holes through ﬂoor of unit in non-designated areas without consulting the factory ﬁrst. The structural integrity of the ﬂoor may be compromised and possible leaks develop.

CAUTION

Internal coil (water, steam or non-integrated direct expansion), WSHP or humidiﬁer piping connections within the unit may only be ﬁeld extended through the cabinet within designated areas. The unit cabinet and/ or ﬂoor must be wisely penetrated in order to keep their integrity. Access openings in the ﬂoor can only be cut or drilled for piping and wiring (high and low voltage) in the designated rectangular areas within an upturned 1” [25.4 mm] ﬂange as provided during the submittal process and located on the mechanical drawings. Access openings must be sized, ﬁeld cut or drilled by the Installing Contractor within the rectangular ﬂanged area then sealed air and water-tight. If insulation was removed to create ﬂoor access openings, insulation must be put back in place to avoid condensation. Do not cut or drill holes through ﬂoor of unit in non-designated areas without consulting the factory ﬁrst. The structural integrity of the ﬂoor may be compromised and possible leaks develop.

Connections to the unit coil (water, steam or non-integrated direct expansion, WSHP or humidiﬁer) are by others. Refer to the mechanical drawings and the instructions on the casing for correct orientation of external piping. External supply and return piping connection, provision, design and all other safety, freeze protection or electrical control requirements for system operation are the sole responsibility of the Installing Contractor and/or Design Engineer. Refer to ASHRAE handbooks and local building codes for correct piping and electrical control for proper

installations. Refer to the mechanical drawings for coil performance design information.

For WSHP units see Appendix B for recommended piping and electrical control components. See the piping schematics for optional piping components and sequence of operation for electrical control options or interlocks supplied with the unit.

CAUTION

A water and glycol mixture is used for factory tests and to prevent any possibility of freezing during transit and/ or storage. In units that include factory installed water piping, some glycol may remain in the system. Flush the system in the ﬁeld, prior to installation, if no glycol traces are desired. In low temperature applications, the water supply line and return line should be insulated to prevent condensate and an antifreeze solution should be used to protect water-to-refrigerant heat exchanger from freezing damage.

IMPORTANT

A hydrostatic test must be performed in the ﬁeld by the Installing Contractor at 1.2 times the operating pressure on all equipment involving piping connections to verify that the installed unit and its connections to the network are free of leaks prior to the unit being set in operation. This test shall be performed after the unit is completely piped to the network and shall cover the connections between the unit and the network, as well as all internal components of the unit.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 21

Condensate Drain Trap and Lines

Cooling coils, humidiﬁers, sensible heat exchangers or other options that can produce condensation are provided with a drain pan with a 1¼” [32 mm] MPT (Male Pipe Thread) drain connection. A drain trap and condensate line of equal size must be ﬁeld provided by the Installing Contractor on the drain connections and coupled to the building drainage system to prevent air or sewer gases from being pulled into the unit caused by the negative (suction) pressure and forcing water out of the pan into the unit or from air escaping into the drain caused by positive pressure. Condensate piping can be steel, copper or PVC. See Appendix C for illustrations and dimensional information on positive and negative pressure trapping height. Slope the drain lines downward in direction of

Gas Connections

Refer to Appendix D for gas-ﬁred furnace installation and maintenance information.

ﬂow not less than 1/8” per foot toward the building drainage system; otherwise use a condensate pump. Refer to local codes for proper drainage requirements. Installing a plug for cleaning of the trap is recommended. Fill the P-traps with water before starting the unit. Winterize the drain line before freezing on outdoor units. Under some conditions, heat tracing may be required on the drain pipe.

Check and clear drains annually at start of cooling season. Drainage problems can occur should drains be inactive and dry out, or due to reduced water ﬂow caused by buildup of algae. Regular maintenance will prevent these from occurring.

Refrigerant Systems

On assembled units which are split for shipment or by customer request, where the refrigeration system is split, the refrigerant lines are capped at the splits, factory leak tested and charged with nitrogen. The type of refrigerant and charge is based on calculated volumetric capacity and stamped on the nameplate. The Installing Contractor is responsible for connecting the refrigerant lines, leak testing, evacuation, charging the refrigerant system and adjusting the charge.

Start-up

Pre Start-up Check

Before requesting start-up, check that the installation is complete and unit is ready. Complete the pre start-up below (if items are applicable) and the checklist in Appen-

dix E for each unit. For torque values on set screws, belt

tension, energy wheel seal clearance, etc. check under the appropriate Maintenance and/or Appendix sections.

1. Check the electrical disconnect is in the ‘Off’ position.

2. Check the split section joints are properly installed on multi-section units.

3. Check that all holes that have been made by the Installing Contractor after receiving the unit in the casing, partitions or ﬂoor have been well sealed to prevent air and/or water inﬁltration.

On assembled units with split refrigerant systems where the condenser or condenser/compressor sections are remotely installed, the Installing Contractor is responsible for designing and completing the refrigerant system, calculating the charge, leak testing, evacuation, charging the refrigeration and adjusting the charge.

Refer to Appendix P for information on adjusting the refrigerant charge.

4. Check the unit for obstructive packaging, objects near or in fans, dampers, energy recovery wheel, etc. a. Check that the inside of the unit has been

cleaned of all debris.

5. Remove all retaining bolts on fan isolation bases. a. Check that the fan impellers are rotating freely. b. Check fan impeller and drive set screws. Tighten

if required.

c. Check the fan bearing set screws or locking col-

lars. Tighten if required. d. Check fan belt alignment and tension. e. Check the fan ﬂexible joint connections are well

attached.

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Page 22

6. Check that the air ﬁlters are installed and clean. Replace if necessary. See Appendix F for optional downstream high efﬁciency HEPA ﬁlter installation (if supplied). a. Check all face mounted ﬁlters are attached with

four clips each.

b. Check each sliding ﬁlter has a retainer at the end

track and well attached blank-offs.

c. Check the ﬁlter pressure differential gauges,

switches or sensors are free of dirt and set at a value satisfactory to the end user to trigger a ﬁlter change.

7. Check coils if ﬁns have been damaged in shipping, installation or building construction and are clean. Straighten ﬁns with ﬁn comb and clean coil if required (not applicable to brazed aluminum heat exchangers). a. Check all pipe connections are tight and that

no damage has occurred during shipping or installation.

b. Check that the piping to the coils and WSHP

have been completed, piping lines have been ﬂushed, ﬁlled, vented and tested at 1.2 times the operating pressure. Refer to Appendix B.

8. Scroll compressor RIS vibration isolator bolts are factory tightened to the correct torque setting for operation and do not require ﬁeld adjustment. a. Check the refrigerant components and piping are

in good condition and have no damage or leaks from shipping or installation.

b. Check that the refrigerant lines are spaced at least

1” apart and from the compressor after shipping and installation.

c. Check that the refrigerant line clamps are still secure

and have their rubber lining.

d. Check that the clearance around the air cooled

condenser is within minimum clearance and the discharge is not blocked.

9. Check motorized damper control arms, control rods and shafts for tightness. a. Check that non-motorized dampers rotate freely.

10. Check the energy recovery wheel media for any defects from shipping or installation. See Maintenance section for details. a. Grease both pillow block bearings on the

wheel(s) when grease nipples provided.

b. Check that the wheel(s) are turning freely by

hand and do not bind.

c. Visually inspect the wheel(s) to ensure it is cen-

tered and does not tilt. If there is any indication of a problem call Venmar CES Tech Support at 1-866-4-VENMAR.

d. Check that the wheel seals are properly posi-

tioned from the face of the wheel.

e. Check that the wheel purge (if present) is set to

the default angle as speciﬁed in the submittal.

f. Check the mounting fasteners on the wheel(s)

motor and gear reducer are tight.

g. Check the belt and pulley on the wheel drive for

correct alignment, tension and set screw tightness.

11. Check the plate media for any defects from shipping or installation.

12. Check the heat pipe ﬁns for any defects from shipping or installation. a. Remove retaining bolts on heat pipe tilt mechanism. b. Check the heat pipe ﬂexible connection is prop-

erly attached and sealed on tilt mechanisms.

c. Check that actuator, control arm and linkages

are tight on tilt mechanism.

13. Check that ductwork is connected, complete and free of obstructions.

14. Check that condensate drain connections have been trapped, installed correctly and ﬁlled.

15. Check at all unit split sections that all factory internal high and low voltage wiring connections have been properly re-connected.

16. Check that all shipped loose or ﬁeld supplied components have been correctly installed and wired.

17. Check that the wiring diagram has been marked up accordingly and left with the unit.

18. Check that all power supplies and control wiring have been inspected and approved by the Local Authorities having jurisdiction.

19. Check all factory and ﬁeld wiring connections for tightness. Tighten if necessary.

20. Check that all fuses are properly installed in holders.

21. Check the voltage at the disconnect switch against the nameplate and against phase-to-phase readings on three-phase. If the voltage is not within 10% of rated or 2% of phase-to-phase, have the condition corrected before continuing start-up.

22. Check that all ﬁeld piping and venting installation and connections for the heating and cooling options have been completed and tested.

23. Set the heating and cooling enable switches to the ‘Off’ position.

24. Refer to Appendix D for gas-ﬁred furnace module and Appendix G for electric coil installation and maintenance and check that the installation is complete. Perform all gas-ﬁred furnace and electric coil pre start-up checks.

25. Check that all safety switches, overloads or other manual reset devices are reset.

26. If the unit is equipped with compressors, power must be turned on with the unit in ‘Off’ mode for 24 hours before start-up. This will energize crankcase heaters and assure no liquid refrigerant is present which could cause compressor damage or failure. Check that this has been completed.

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Page 23

Start-up Procedure

To ensure proper operation of each unit, qualiﬁed personnel should perform the start-up as outlined below (based on options included with unit) and complete the Start-up Report and Checklist in Appendix E for permanent record. A completed report and checklist will provide valuable information for personnel performing future maintenance.

IMPORTANT

• A completed copy of the Start-up Report and Checklist must be sent back to the factory for warranty validation and for factory assistance.

• General information on the factory installed and programmed DDC control system regarding the navigation and monitoring of the unit with the standard keypad are provided in separate documents. For more speciﬁc information regarding the sequence of control, the different options of control or network communications, see these documents included with the unit in the control panel pocket.

• If units are equipped with compressors power must be turned on for 24 hours prior to a call for cooling, for the compressor crank case heaters to be energizing to prevent possible damage.

• Assembled units with integrated refrigerant systems (AC, WSHP or ASHP) are factory leak tested, charged with refrigerant based on volumetric capacity and run tested prior to shipment with the type of refrigerant and charge stamped on the nameplate. As part of the start-up procedure, operate the refrigerant system near full load conditions in both heating and cooling modes and check sub-cooling and superheat against values in Appendix P, Table

P1. If readings do not match, adjust the refrigera-

tion charge. Refer to Appendix P for information on adjusting the refrigerant charge.

WARNING

• Electric shock can cause personal injury or death.

• Only qualiﬁed service personnel should install and service this equipment.

• The keypad must be used to check operation according to sequence and to adjust setpoints while power is on for start-up and while performing service.

• All units are factory run tested. Fans, energy recovery wheel, compressors and condenser fans (if equipped and refrigerant piping is not split for shipment) are set up to run correct when power is connected. If any one fan is running backwards or compressor is making loud noises, disconnect power and switch two leads (on three-phase power) to ensure proper rotation and avoid damage. With multi-section units with split wiring connections check rotation of fans, energy recovery wheel, compressors and condenser fans for correct rotation to ensure wiring connections are correct.

1. Before proceeding, complete the pre start-up checklist.

2. Check that all access panels or doors are closed.

3. If units are equipped with compressors, feel the compressor crank cases. They should be warm if the disconnect has been on for at least 24 hours. This will assure that no refrigerant liquid is present in the crank case which could cause compressor damage or failure to occur on start-up. Otherwise turn the main disconnect to the ‘On’ position.

4. The unit can be started by using the keypad and selecting the mode of operation from the Keypad Operation Guide and the Sequence of Operation. Disable the heating and cooling functions and set the unit to the occupied mode to bump start the fan wheel(s) and energy recovery wheel(s) to check their operation.

5. Check that dampers are operating properly.

6. Check that the fan wheel(s) and energy recovery wheel(s) are rotating in the correct direction.

7. Adjust the fan motor VFD(s) to the correct air volume/Hertz/

8. For occupied recirculation mode adjust outside, exhaust and mixed or recirculation air damper positioners to achieve the required air volumes.

9. Check amperage draw to each motor on each phase against motor nameplate FLA. If signiﬁcantly different, check ductwork static and/or take corrective action.

10. Re-check the voltage at the disconnect switch against the nameplate and against phase-to-phase readings on three-phase with all blowers operating. If the voltage is not within 10% of rated or 2% of phaseto-phase, have the condition corrected before continuing start-up.

11. Before activating the compressor on WSHP units, check that the water shut-off valves are open and water is circulating through the water-to-refrigerant heat exchanger. Check the incoming line water pressure to ensure it is within design and acceptable limits.

12. Enable the cooling mode of operation. Check if the sound of the compressor is normal or if there is excessive vibration.

13. On units with integrated air cooled condensers check condenser fans are rotating in the correct direction.

14. Check all ﬁeld and factory refrigerant and water piping connections for leaks and correct.

15. Operate the refrigerant system near full load conditions in both heating and cooling modes and check sub-cooling and superheat against values in Appendix P, Table P1. If readings do not match, adjust the refrigerant charge. Refer to Appendix P for information on adjusting the refrigeration charge.

16. On units with WSHP, after a few minutes of operation: a. Check the supply discharge temperature status

on the keypad for cooling air delivery. Measure

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 24

the temperature difference between entering and leaving water. In cooling mode, the temperature difference should be approximately 1.5 times greater than the heating mode temperature difference. For example, if the cooling temperature difference is 15°F [8.3°C], the heating temperature difference should be approximately 7°F to 10°F [3.9°C to 5.6°C]. Alternatively, if a ﬂow measuring valve or pressure gauge connections are included, take the ﬂow reading or pressure drop compared to the submittal information and adjust the shut-off/balancing valve in the return line to the correct ﬂow/pressure drop reading.

b. Measure the temperature difference between

entering and leaving air and entering and leaving water. With entering water of 60°F to 80°F [15.6°C to 26.7°C], leaving temperature should rise through the unit. Should not exceed 35°F [19.4°C]. If the air temperature exceeds 35°F [19.4°C], then the water ﬂow rate is inadequate or the airﬂow rate may be low and a second check may be required after airﬂow balancing.

17. On units with gas-ﬁred furnace module or electric heating coils, check supply air proving interlock switch setting to ensure minimum supply airﬂow prior to burner operation. Set the switch to open below the minimum supply airﬂow on the furnace rating plate.

18. Enable heating options, see start-up and check-out instructions in Appendix D for gas-ﬁred furnace module and Appendix G for electric coil and complete.

19. For electric heating coil option, check the amp draw on each stage, the operation of the sequence or SCR controller and the coil for any hot spots.

20. Check the operation of the control options provided on the unit.

21. Check the setpoints on the DDC Points Reference, adjust and record changes as required.

22. Has air balancing been completed for both occupied and unoccupied operation?

23. When unit has achieved steady state, take measurements and complete Start-up Readings portion of the Start-up Report and Checklist in Appendix E. Send a copy of the completed Start-up Report and Checklist to Venmar CES to validate warranty. Maintain a copy of the report at the unit for future reference.

24. Once completed, return setpoints to original or required values, return the unit to the correct mode of operation and adjust the time clock if required.

IMPORTANT

Before measuring supply and exhaust ﬂows, the building must be in its normal state:

• Hermetically close doors and windows.

• Shut down hot air generators and combustion water heaters.

• Install all ventilation system components (ﬁlters, grilles, diffusers, etc.).

For proper performance the unit must operate at the speciﬁed supply and exhaust ﬂow rates as shown in the mechanical drawings. Unit fan speed(s) and damper positions are theoretically set at the factory based on the ductwork static pressures and ﬂow rates speciﬁed in the mechanical drawings. If conditions change or veriﬁcation is required, airﬂow measurements should be taken using AMCA suggested methods. This would normally be a velocity traverse measurement or ﬂow measuring station (FMS) installed in the ducts. Where space is limited in the outdoor air and exhaust air, pressure drop readings can be taken across

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Airﬂow Balancing

the energy recovery heat exchanger (with economizer heat recovery bypass dampers closed, if equipped) and compared to the submittal documents. Heat recovery performance is tested in accordance to AHRI Standard 1060 and is accurate to within +/− 5% if there is no dirt buildup in the heat recovery heat exchanger. Should ﬂow rates need to be reset, adjust the outside air, exhaust air or mixed air dampers, variable speed sheaves, VFD fan speed setpoint positions or change the sheaves.

Flow measuring stations and magnehelic gauges can also be used to measure supply and exhaust ﬂow. It is important to locate the FMS in the “warm side” ductwork to minimize the effect of differences in air density, especially when balancing during extremely cold outside conditions or to take temperature readings and make the necessary corrections if installed in the “cold side” ductwork. Air density variations can affect the FMS by more than 15%. The FMS should be located downstream in straight sections of duct and not immediately after fans or obstructions that will cause turbulent ﬂow.

Page 25

If the unit has been in operation before the air balancing,

Spoke

Seal

Drivin belt

Motor base

Enthalpy

ensure the unit ﬁlters are clean or include pressure drop readings across the ﬁlter banks with the report.

Refer to Appendix D for gas-ﬁred furnace module air balancing information. The installation is to be adjusted to achieve the air throughput within the range speciﬁed on the gas-ﬁred furnace module rating plate.

Maintenance

Long-term Storage Maintenance Procedures

CAUTION

Imbalanced airﬂows may cause supply air temperatures to be below freezing. Adequate freeze protection, glycol, low limit temperature protection for downstream coils or reheat to protect building systems must be ﬁeld provided.

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

Maintenance Summary Chart

Please refer to Appendix I, for a recommended list of routine maintenance items and time intervals. A more detailed description of maintenance items follows.

Energy Recovery Wheel

The energy recovery wheel will provide years of effective and efﬁcient service with minimal maintenance. Basic maintenance consists of checking parts to ensure they are tight and working correctly. Venmar CES recommends that the wheel be checked on a weekly basis that it is turning under power if not equipped with a rotation detector alarm. Completing the items described further in the Maintenance Summary Chart in Appendix I will ensure the wheel is running at its maximum efﬁciency and assist with the early detection of anything that may cause problems in the future. If removal or replacement does become necessary contact the factory for instructions.

Please refer to Appendix H for maintenance instructions to follow if the unit is to be stored for a period of time exceeding one month. Following the instructions in this appendix will assist in preventing potential unit damage that may result from an extended storage period.

Rotation

Outside/supply

air side

Media

segment

Purge

Return/exhaust

air side

Casing

wheel

E/A

Outside side

Purge

O/A

Figure 15: Direction of airﬂow through the wheel

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

R/A

S/A

Purge side

Figure 16: Labeled diagram of wheel

Wheel Bearing Lubrication

Recommended lubrication of bearings (when grease nipples provided) varies depending on the temperature range the wheel will be used in. For a typical temperature range of −40°F to 130°F [−40°C to 54°C], lubrication is recommended every six months. For temperatures out of

Page 26

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

this range, please consult Venmar CES for recommended lubrication schedules. Use a premium quality lithium based grease conforming to NLGI Grade 2 or 3 (examples are: Mobil – Mobilith AW2, Chevron – Amolith #2, Texaco Premium RB, Shell Alvania #2).

Wheel Bearing Set Screws

Bearing set screws and mounting bolts (two on each side of the wheel) should be checked for tightness at start-up and every six months thereafter. On wheels 10” deep a special seal lacquer is applied to the bearing set screws and mounting bolts. See Figure 17. This is a visual aid that will warn you if bearing set screws or mounting bolts have become loose during transport or over time should cracks appear. Set screws should be torqued to 13 ft-lb for wheels up to 78” [1,981 mm] diameter and 24 ft-lb for wheels from 88” to 120” [2,235 to 3,048 mm] in diameter.

Figure 17: Enthalpy wheel seal laquer

Gearbox

The gearbox (speed reducer) on the energy recovery wheel has been lubricated for life at the factory and requires no further lubrication. The gearbox requires no maintenance under normal use.

Belts

The energy recovery wheel drive belt is a strong and ﬂexible multi-link which provides quick and easy servicing or replacement without using special tools. The belt is directional; it must be installed with the directional arrows pointing in the direction of motor rotation. See Appendix

K for belt repair and replacement instructions. Checking

the belt every three months for wear is recommended.

Belt Installation

1. Consult Venmar CES for belt length (dependent upon wheel diameter).

2. If required, remove links by twisting the link tabs sideways and pulling the surplus out of the belt.

3. Tape one end of the new belt to the wheel and make it turn (by hand) one complete revolution. Place tapes on the belt to ensure its proper upright position and hold it in place until it will be linked. The wheel should turn freely if the belt is removed.

4. Pull the belt tightly around the wheel and reducer sheave.

5. To connect the two free ends of the belt, hold the belt with tabs pointing outward. Place the end tab through two links at once. Flex the belt further and insert the second tab through end link by twisting the tab with your thumb. Ensure tab returns to position across belt. Reverse belt so tabs turn to the inside of belt.

6. Depending on type of wheel provided, install the extension spring or pass the belt over the tensioner idler sheave. If there is no tension in the spring or tensioner, reduce the length of the belt. If the spring tensioner looks permanently extended, contact the factory for a replacement spring tensioner.

Belt Tensioner Replacement

1. Release the belt from the belt tensioner idler sheave, Figure 18.

Motor Bolts

Bolts securing the motor to the base plate should be checked periodically for tightness at start-up, after one month of operation and annually thereafter (see Table 1 for recommended torque).

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Figure 18: Release belt from belt tensioner idler sheave

Page 27

WARNING

labyrinth seal

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

2. Remove the belt tensioner retaining screw and set aside (see Figure 19).

Figure 19: Remove belt tensioner retaining screw

3. Remove belt tensioner and discard. Install new belt tensioner (contact Venmar CES Tech Support at 1-866-4-VENMAR for parts using description and unit serial number).

4. Ensure that the new belt tensioner line is aligned with one of the bottom corners (see Figure 20).

IMPORTANT

The idler sheave must be pointing upwards.

Seals

Side seal

Peripheral seal

Airloop™ labyrinth seal

Figure 21: Energy recovery wheel seal locations

Depending on size and type of wheel, brush or labyrinth seals are provided. Visually inspect the seals of the energy recovery wheel(s) for proper operation. Brush seals for the side and peripheral seals per Figure 21 are designed to be durable and require no maintenance, but some seal run-in is to be expected, so do not be alarmed by a small amount of wear. Labyrinth seals must be adjusted properly if the unit is to work effectively and efﬁciently; the correct adjustment of the labyrinth seal is obtained by allowing it to barely touch the media before tightening the screws (see Figure 22). If an initial gap can be seen between the seal and media, the seal is installed too far and should be moved closer until it touches the media. On the other hand, if any deformation to the lips can be seen, it means the seal is installed too close and should be moved back until the lips are straight again.

It should be noted that the labyrinth seal is made of a special material which was speciﬁcally chosen to make sure it could never damage the media. While the best seal is obtained when the above steps are followed, if installed too close, the media will simply use the seal a little more.

Airloop™

Figure 20: Energy recovery wheel seal locations

5. Reinstall and tighten screw.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

As the wheel turns, the seal will automatically adjust itself to the wheel’s tolerance (approximately 1/32”) for the smallest possible air leakage and become a non-contact seal that will last throughout the wheel life.

To ensure optimal performance, seals should be checked at time of start-up, after one month of operation and every three months thereafter. Labyrinth seals, if found to be out of tolerance, should be adjusted immediately.

Page 28

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

Wheel media

Too close

Correct

d2 = 0” (start-up) d

’ = Wheel tolerance

Wrong

Too far

Wrong

The opposing airﬂow pattern through the wheel allows for self-cleaning and if the air ﬁlters on both airstreams are properly maintained there should be minimal dirt buildup. If the wheel media has become restricted with dirt and needs cleaning use low pressure (20 psi maximum) compressed air or vacuum. If this is insufﬁcient, please contact the factory for further instructions. When cleaning the wheel, protect the motor and other components from contamination. Solvents or detergents are not recommended for use as they may degrade the binding used for the desiccant in the media.

CAUTION

Energy recovery wheel cleaning is an important part of routine maintenance. The listed methods of cleaning have been found effective, if done properly. However, any method of cleaning has the potential to cause damage to an enthalpy wheel media or desiccant if done improperly.

Venmar CES is not liable for any damage caused as a result of energy recovery wheel cleaning.

Figure 22: Airloop™ labyrinth seal adjustment

Wheel Media

Periodic checking of the media, rim, spokes and shaft is very important in maintaining optimal performance of the wheel. To check the media, the wheel must be shut down. The media should be checked for tightness at start-up, after the ﬁrst 30 days of operation, then by three month intervals. The best method to test for tightness is to place your hands against the media, near the hub, and try to move it up and down on both sides. This procedure should be used on all segments of the wheel. If any movement, in any direction, is detected on any segment, contact Venmar CES immediately.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 29

Flat Plate Heat/Enthalpy Exchangers

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

Venmar CES offers four types of plate heat/enthalpy exchangers. They are factory installed and ready to use upon receipt. Based on long experience, dirt buildup inside the plate heat exchangers installed in air handling equipment is not expected, provided the air ﬁlters on both airstreams are properly maintained. Plate heat exchangers should be visually checked monthly for dirt buildup on the entering face for the initial three months after installation and start-up, after which checks should be carried out every 12 months. During normal operation or when used for special applications (e.g. welding shops, paint shops, kitchen extracts, etc.), should dirt enter the plate heat exchanger, if pressure differential between exchanger inlet and outlet is higher than stated at the design airﬂow, clean the exchanger using techniques mentioned below. If after cleanup, the pressure differential is still higher than stated at the design airﬂow, contact Venmar CES.

Extruded polypropylene and corrugated or embossed aluminum plate heat exchangers should be cleaned by removing dust and ﬁbers with a soft brush, a vacuum cleaner or with dry compressed air at 90–95 psi and 12”[305 mm] from the surface. Take care when cleaning with compressed air that the exchanger is not damaged and that oil contained in the compressed air is not pushed inside. Oils, solvents, etc. can be removed with hot water, harmless grease solvents or cleansing agents by washing. If using a high pressure device use a ﬂat 40° nozzle (type WEG40/04) with a maximum water pressure of 1,450 psi [100 bar] and 12” [305 mm] from the surface. Take care when cleaning with water, solvents or cleaning agents that the exchanger is not damaged, either mechanically or chemically.

Enthalpy (sensible and latent) plate heat exchanger core is constructed of alternate layers of corrugated aluminum material and polymeric desiccant impregnated media and should be cleaned by removing dust with a soft brush or with a vacuum cleaner only.

CAUTION

Do not use compressed air or water to clean an enthalpy

plate heat exchanger as irreparable damage may occur.

Heat Pipe Heat Exchangers

Heat pipes are factory installed and ready to use upon receipt. Based on long experience, dirt buildup inside the heat pipe heat exchangers installed in air handling equipment is not expected, provided the air ﬁlters on both airstreams are properly maintained. Heat pipe heat exchangers should be visually checked monthly for dirt buildup on the entering face for the initial three months after installation and start-up, after which checks should be carried out every 12 months.

During normal operation or when used for special applications (e.g. welding shops, paint shops, kitchen extracts, etc.), should dirt enter the heat pipe heat exchanger, if pressure differential between exchanger inlet and outlet is higher than stated at the design airﬂow, clean the exchanger by removing dust and ﬁbers with a soft brush, or with a vacuum cleaner. Oils, solvents, etc. can be removed with hot water, grease solvents or cleansing agents by washing. Choose harmless grease solvents or cleansing

agents in accordance with the heat exchanger material (raw aluminum or coated tubes) such that they will not contaminate or release volatile organic compounds (VOCs) into the treated air and area(s) the unit serves. If using a high pressure device, use a ﬂat 40° nozzle (type WEG40/04) with a maximum water pressure of 1,450 psi [100 bar] and 12” [305 mm] from the surface. Take care when cleaning with water, solvents or cleaning agents that the exchanger is not damaged, either mechanically or chemically. If after cleanup, the pressure differential is still higher than stated at design airﬂow, contact Venmar CES.

If the heat pipe heat exchanger is equipped with a tilting mechanism, the linkage, actuator mounting attachments, bearing attachments and ﬂexible connection attachments and condition should be checked for tightness before start-up, after the ﬁrst week of operation, then on three month intervals.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 30

Refrigerant Systems

Distributor

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

Compressors

Scroll type compressors are the most common type of compressor used by Venmar CES. Other types of compressors are available upon request, if required.

Maintenance and service on compressors must be completed by a licensed service mechanic. Provincial or state regulations frequently require such qualiﬁcations for compressor maintenance.

If a compressor cycles, leaks or has any defects, contact Venmar CES as soon as possible.

See Appendix B for compressor maintenance and troubleshooting refrigerant circuits and Appendix P for adjusting refrigerant charge. Additional refrigerant troubleshooting issues can be found in Appendix O.

Condenser

Condenser Fans and Motors, Air Cooled

The units contain direct drive condenser fan and motor assemblies. The condenser fans are multi-blade propeller type with die cast silumin alloy hub and glass reinforced polypropylene or polyamide industrial quality adjustable pitch high performance blades. The motors are threephase, 1,140 rpm and are of the heavy duty type complete with permanently lubricated ball bearings, inherent threephase protection and NEMA Class B insulation.

Motor shafts are coated for rust protection. Each motor is mounted on a heavy duty bracket which is constructed of heavy gauge steel. Fan guards are furnished on the top for safety purposes. Fan guards are constructed of heavy gauge close meshed steel wire. The fan outlet venturi is constructed of galvanized steel. The condenser fan motors are cycled to provide head pressure control down to 50°F [10°C] ambient.

gaskets do not require renewing at every maintenance operation. However, if the head gasket is physically disﬁgured or deteriorated in any way, the system will require new gaskets in order to retain the water-tight seal.

Periodically plate and coaxial heat exchangers should be chemically cleaned to ensure optimum condenser efﬁciency. Frequency of cleaning will depend on individual water conditions hence a suitable cleaning schedule should be arranged based on experience and knowledge of the building or local water supply loop.

Condenser Coils, Air Cooled

Condenser coils may be constructed of aluminum or copper ﬁns that are mechanically bonded to copper tubes or alternately may be constructed of high performance aluminum microchannel tubes, ﬁns and manifolds that have been brazed to form a complete refrigerant-to-air heat exchanger coil. An integral liquid sub-cooler circuit designed for 10°F [5.6°C] subcooling is also provided to minimize the possibility of liquid ﬂashing while maximizing the cooling capacity of the system.

Evaporator Section

The direct expansion coil is constructed of seamless copper tubing expanded into full collared aluminum ﬁns. The tubes are arranged for a counter ﬂow circuit and staggered to provide maximum heat transfer. A pressure type distributor with hot gas inlet port and a heavy duty copper suction header are included. Additional refrigerant circuit components include thermostatic expansion valves with external equalizer and insulated suction lines in the airstream.

Components of a Direct Expansion (Dx) System

The evaporator is that part of the low pressure side of the refrigerant system in which the liquid refrigerant boils or evaporates, absorbing heat as it changes into a vapor.

Condensers, Water Cooled

Water cooled units may contain either plate, shell and tube and coaxial water cooled condenser. Water source heat pump units may contain either plate and coaxial water cooled condenser/evaporator.

Periodically tubes in the shell and tube condenser should be mechanically cleaned to ensure optimum condenser efﬁciency. Cleaning brushes are available from most refrigeration supply outlets. For better results, always remove both heads before cleaning water tubes. Note that head

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Liquid line

Hot gas bypass line

Suction line

Expansion valve

Check valve on remote condensing application (optional)

Evaporator coil

Figure 23: Direct expansion (Dx) coil

Thermostatic Expansion Valve

The Thermostatic expansion valve (TXV) is a precision device designed to meter the ﬂow of refrigerant into the

Page 31

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

evaporator, thereby preventing the return of liquid refrigerant to the compressor. By being responsive to the temperature of the refrigerant gas leaving the evaporator and the pressure in the evaporator, the thermostatic expansion valve can control the refrigerant gas leaving the evaporator at a predetermined superheat.

Three forces that govern the operation of the TXV are: the pressure created by the remote bulb and power assembly (P1), the evaporator pressure (P2) and the equivalent pressure of the superheat spring (P3).

Dampers

Bulb clamp

Remote clamp

Diaphram

External equilizer port

Figure 24: Thermostatic expansion valve (TXV)

Units from Venmar CES usually come with two sets of dampers. However, units may have more than two sets if the unit has been ordered with the recirculation or face and bypass frost control options. Outside air dampers and return air dampers can be motorized or gravity activated. The following maintenance should occur in order to prevent the unit from working under too much pressure and to prevent freezing issues.

Dampers must be kept free of foreign matter that might impede normal free movement. Bearings between blades and frames are made of polymer and require no maintenance. Note that the damper shafts do not need lubrication. All Venmar CES dampers and linkages are assembled with non-lubricating bearings.

• Attachment mechanism linking motors to dampers should be checked for tightness.

• Damper jackshafts (if provided) are ﬁtted with grease nipples and should be lubricated once a year. Use a premium quality lithium based grease conforming to NLGI Grade 2 or 3 (examples are: Mobil – Mobilith AW2, Chevron – Amolith #2, Texaco Premium RB, Shell Alvania #2).

• Dampers should be inspected for dirt; check the shaft, arms, bars and controls rod every three months.

• Inspect the seals to ensure none have pulled loose or deteriorated. If a seal has been damaged, repair or replace it with the same seal or same seal material. Contact Venmar CES for replacement parts.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 32

Belt Driven Fans

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

Belt driven fan, motor and drive assemblies should be checked and inspected at regular intervals per the inspection list and procedures below. Listen for vibrations or unusual sounds. Severe damage, premature failure and loss of airﬂow can be avoided by regular inspection and maintenance.

1. Check the fan, motor and bearing mounting bolts for tightness according to the bolt torque chart in Table 1 below at time of start up, after 24 hours, then every three months.

Table 1: Minimum head bolt torque in lb-ft (Grade 5 bolts)

Size (Inches) Thread Designation Minimum Torque

1/4 –20 1/4–28 5/16–18 5/16–24 3/8–16 3/8–24 7/16–14 7/16–20 1/2–13 1/2–20 9/16–12 9/16–18 5/8–11 5/8–18 3/4–10 3/4–16 7/8–9 7/8–14 1–8 1–14

Soft metric conversions are not acceptable for screw and hex sizes.

2. Check the fan wheel hub, bearings and drive sheaves set screws for tightness according to the set screw torque chart in Table 2 at time of start-up, after 24 hours of operation, monthly for the initial three months then every three months. If wheel or bearing set screws have worked loose check the wheel for any signs of movement (inlet space clearance between the fan wheel and housing) or loose blades. If Loctite was used on any set screws that have come loose the set screws must be removed and cleaned before re-tightening and Loctite must be re-applied.

UNC

UNF

UNC

UNF

UNC

UNF

UNC

UNF

UNC

UNF

UNC

UNF

UNC

UNF

UNC

UNF

UNC

UNF

UNC

UNF

7 14 16 24 28 42 45 69 83 99

118 150 176 254 301 358 422 500 602

Table 2: Wheel set screw torque in lb-ft

Set Screw Size

Diameter (Inches)

1/4 75 6.2

5/16 144 12.0

3/8 252 21.0

7/16 396 33.0

1/2 600 50.0 5/8 1,164 97.0 3/4 2,016 168.0 7/8 3,204 267.0

1 4,800 400.0

*Stainless steel set screws are not hardened and should not be tightened to more than half the values shown.

Carbon Steel Set Screw Torque*

lb-in lb-ft

3. Check each V-belt tension and adjust the motor base for correct amount according to the deﬂection outlined in the Measuring Belt Tension procedure below and in Appendix J for type of belt at time of start-up, daily for the ﬁrst week until they should acquire their permanent set, then monthly. All belts should have approximately the same amount of deﬂection. Be aware of mismatched or worn belt sets. If a belt must be changed, ensure to change all belts on the same drive at the same time. Never replace just one belt within a set.

Table 3: Bearing set screw torque in lb-in

Set Screw

Diameter

#10 40 — 35 35 —

1/4 90 65 50 85 —

5/16 185 125 165 165 160

3/8 325 230 290 290 275

7/16 460 350 350 — —

1/2 680 500 620 — 600 5/8 1,350 1,100 1,325 — 1,200 3/4 2,350 — — — 2,000

Split pillow block bearings are ﬁxed to the shaft with tapered sleeves and generally do not have set screws.

Link Belt

Manufacturer

Sealmaster SKF McGill Dodge

Measuring Belt Tension

a. Measure the belt span with a span scale. b. Divide the belt span by 64 to determine the belt

deﬂection needed to check tension.

c. Set the O-ring on the span scale to the required

deﬂection value. d. Set the small O-ring at zero on the force scale. e. Place the scale end of the tension checker

squarely on one belt at the center of the belt

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 33

WARNING

sheave

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

span. Apply force on the plunger until the bottom of the large O-ring is even with the top of the next belt or until it is even with a straight

f. Read the force scale under the small O-ring to

determine the force required to give the needed deﬂection.

g. Compare the force scale reading in Step F with

the correct value for the belt style and cross section. The force scale reading should be between the minimum and maximum values shown in Ap-

pendix J.

h. If the deﬂection value is below the minimum,

tighten the belts. If the deﬂection value is above the maximum, loosen the belts. The tension on new belts should be checked during the ﬁrst day of operation, at the end of the ﬁrst week and monthly thereafter.

4. Check the fan and motor sheave alignment using a straight edge along the outside edges of the sheaves for equal sized ﬁxed sheaves as shown in Figure 25 and Figure 26 at time of start-up, after 24 hours of operation, monthly for the initial three months, then every three months. When properly aligned, the straight edge should touch the full face of both sheaves. With one adjustable and one ﬁxed sheave with unequal sizes, use a string placed at the center grove of both sheaves pulled tight to check alignment. Adjust sheaves for proper alignment and set screws to proper torque.

5. Belt driven fan bearings are ﬁtted with grease nipples for lubrication. The grease quantity and lubrication interval depends on bearing (fan size) and rpm and are indicated in the tables in Appendix L. Use a premium quality lithium based grease conforming to NLGI Grade 2 or 3 (examples are: Mobil Mobilith AW2, Chevron Amolith #2, Texaco Premium RB, Shell Alvania #2 or ESSO Beacon #325). Clean the grease nipple ﬁrst, then rotate the fan shaft slowly by hand while adding grease. The lubrication intervals are theoretical and will depend on site conditions, hours of operation and temperature. It is recommended to make periodic inspections of the bearings before these theoretical intervals.

6. Fan wheels, housings and drive assemblies should be checked for dirt buildup annually and cleaned if necessary to keep them from becoming unbalanced and to prevent loss of airﬂow. Clean with compressed air to reduce any dirt, dust, lint or larger particulates that have bonded to the fan impeller housing or drive assembly. Block dirt from entering the unit and ductwork if necessary or remove fan assembly from unit. Alternatively use low pressure steam, a degreaser and rag. If a sheave requires cleaning, detergent and water can also be used. Ensure the belt is dry before starting up the unit.

IMPORTANT

Be careful not to remove or dislodge balancing clips on the fan blades while cleaning.

Center lines must coincide

Fixed sheave

Adjustable

Figure 25: Equal sheave size alignment

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Figure 26: Unequal sheave size alignment

Lines must be parallel

Straight edge

Page 34

FANWALL® Array

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

Maintenance Schedule

FANWALL array of multiple direct driven plenum fan and motor “cubes” are equipped with permanently sealed bearings and do not require lubrication. The following maintenance schedule is recommended.

Monthly

• Check the fan wheel to inlet cone alignment for possible noise from the wheel rubbing against the inlet cone. See Fan Wheel/Cone Alignment below for instructions.

Every six months

• Check motor bearings for possible binding noise or overheating.

• Check fan wheels for dirt and grease accumulation. Clean as necessary. Do not use any caustic cleaning solutions.

Annually

• Lightly lubricate damper and linkage bushings on back draft dampers (if equipped).

Every Two Years

• Examine fan housings and motor pedestal for corrosion. Clean and touch up with paint as necessary.

Figure 28: Remove safety screen on motor end

3. Disconnect the four-wire electrical cable from the motor junction box. Make note of wire locations for reinstallation later. See Figure 29.

Figure 29: Remove electrical cable

4. Mark motor pedestal location on the motor pedestal mounting angles (both sides), then loosen and remove (4) ½” bolts that retain the motor pedestal to the mounting angles. See Figure 30.

Figure 27: FANWALL array

Fan Wheel and Motor Removal

1. Disconnect power to the fan array control panel before maintenance. Follow all lockout and tag out procedures.

2. Remove the optional safety screen (if provided) on the motor end only of the cube in question by removing all four hex screws from the holding ﬂange that retains the safety screen. See Figure 28.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Figure 30: Remove motor pedestal retaining bolts

Page 35

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

5. After removing the motor pedestal retaining bolts, slide the motor/fan/pedestal assembly out to the point where the motor lifting ring is clear of the cube frame enough to use. If a mechanical device is available for use, attach it to the motor lifting ring. Lift and remove the motor pedestal with motor and fan wheel from the cube. The motor pedestal with motor and fan wheel can be turned 180° and slid back into the cube on the pedestal mounting angles or removed from unit for further disassembly.

6. Mark the location of the trans-torque bushing on the shaft and the fan. To remove the fan wheel from the motor shaft, remove the trans-torque bushing retaining hex nut using a 1” socket with a 12” extension by turning counter clockwise. Loosen progressively until the bushing is free from wheel hub and motor shaft. Remove fan wheel/hub assembly. See Figure 31.

Figure 31: Mark location and remove trans-torque bushing and fan wheel from motor.

7. If needed the motor may now be removed for service by removing all (4) 3/8” motor retaining nuts and bolts. Be sure to mark the motor base pattern and bolt holes used on the motor pedestal. Rubber isolator pads between the motor base and the pedestal are optional and if supplied be sure not to lose them. See Figure 32.

Figure 32: Remove motor retaining bolts; do not lose rubber isolator pads (if provided).

8. To reinstall the motor, fan wheel and fan wheel/ motor/pedestal assembly back into the cube, reverse the steps above noting the following: a. Insert the (4) 3/8” motor retaining bolts into the

holes in the motor pedestal from the underside; make sure to use a standard washer on the bolt side, install the rubber isolator pads (if supplied) between the pedestal and motor base and only a locknut is required on the motor side.

b. Square the motor on the pedestal according to

markings and tighten the bolts. With rubber isolator pads tighten the bolts to 20 ft-lbs. Without rubber isolator pads tighten the bolts to 40 ft-lbs.

c. Install the fan wheel on the motor shaft with the hub

facing towards you. Line up the markings on the hub/trans-torque bushing/shaft. Make sure that the trans-torque bushing nut is ﬂush to the hub. Tighten the bushing nut progressively to 80 ft-lbs turning clockwise.

9. Lift the motor pedestal with motor and fan wheel (turn 180° if placed on the pedestal mounting angles for disassembly) with the fan wheel inlet toward the inlet cone. Place motor pedestal into the cube on the pedestal mounting angles and slide the pedestal forward to the line that you previously marked. Line the four pedestal bolt holes up with the bolt holes on the mounting angles. Insert (4) ½” bolts into the holes, make sure to use a standard washer on the bolt side and a standard washer and lock washer on the nut side. Hand tighten the bolts for now.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 36

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

Figure 33: Check fan wheel/cone alignment and overlap.

10. Check the inlet cone alignment to the fan wheel. Fan wheel should not be rubbing against the fan inlet cone when rotated by hand. The fan wheel to inlet cone clearance should be approximately 1/16” gap and the overlap should be as indicated in Appen-

dix M for the fan wheel size. Adjust the overlap of

the wheel and cone by moving the motor pedestal forward or back. Fan wheel should not be rubbing on the inlet cone. If cone alignment is required see instructions for Fan Wheel/Cone Alignment below. Once alignment and overlap are correct, tighten the (4) ½” pedestal mounting bolts to 90 ft-lbs.

11. Reconnect the four-wire electrical cable from the motor junction box. Before operation, start the motor slowly to ensure the fan rotation is correct. If the fan wheel is not rotating correctly, check the motor leads for proper installation. a. Drive Side – Clockwise rotation when looking at

motor end

b. Inlet side – Counter-clockwise rotation looking at

fan inlet

IMPORTANT

Before restarting, re-balance the fan wheel once the motor rotation and alignment have been corrected before placing the unit in operation.

purpose of the damper is so that maintenance staff can block the intake of a single fan to prevent back ﬂow until service on an inoperative assembly can be performed. Note the directions of the damper blades are running vertical. The damper is installed directly onto the FANWALL

cube inlet side panel and over

the optional airﬂow straightener (if supplied).

Figure 34: Fan wheel/cone alignment – Step 2a

Figure 35: Fan wheel/cone alignment – Step 2b

3. If the optional airﬂow straighteners are furnished on the inlet side of the fan it must be removed next. Remove all tek screws on the airﬂow straightener panel frame and remove it from the cube.

Fan Wheel/Cone Alignment

1. To align fan wheel/cone, ﬁrst disconnect power to the fan array control panel. Follow all lockout and tag out procedures.

2. If the optional backdraft damper is furnished on the inlet side of the fan it must be removed ﬁrst. Remove all tek screws on all sides attaching the damper frame to the inlet side panel and remove it from the cube. The

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Figure 36: Fan wheel/cone alignment – Step 3

Page 37

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

4. Gently rotate the fan wheel to verify location of adjustment required.

Figure 37: Fan wheel/cone alignment – Step 4

5. To make adjustment, loosen (do not remove) all the cone retaining fasteners.

7. Gently rotate the fan wheel to verify cone adjustment for proper clearance from wheel.

Figure 40: Fan wheel/cone alignment – Step 7a and Step 9a

Figure 38: Fan wheel/cone alignment – Step 5

6. Using a rubber mallet, gently tap around the cone until desired clearance is acquired between fan wheel and inlet cone.

Figure 41: Fan wheel/cone alignment – Step 7b and Step 9b

8. Tighten all the cone retaining fasteners.

Figure 42: Fan wheel/cone alignment – Step 8

9. Once again gently rotate the fan wheel to verify cone alignment.

10. To install the optional airﬂow straightener or backdraft damper reverse the steps above.

Figure 39: Fan wheel/cone alignment – Step 6

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 38

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

Blank-off Plate (if applicable)

1. Optional blank-off plate(s) are available so that maintenance staff can block the intake of a single fan to prevent back ﬂow until service on an inoperative assembly can be performed or it can be mounted on spare FANWALL® cube(s) until they are required to be put into service.

2. First disconnect power to the fan array control panel. Follow all lockout and tag out procedures.

3. The blank-off plate is ﬁtted to the inlet side of the FANWALL cube on the optional airﬂow straightener panel frame (if supplied) or onto a matching “Z” frame. There are 12 pre-drilled holes which are located in the corners and middle of the airﬂow straightener panel frame or “Z” frame matching pre-drilled holes in the blank-off plate for fastening together with tek screws.

4. Place the blank-off plate over the optional airﬂow straightener panel frame (if supplied) or onto the matching “Z” frame and pre-drilled holes and fasten together with or remove tek screws.

Figure 44: Blank-off plate – Step 4

Figure 43: Blank-off plate – Step 3

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 39

Motors

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

Motors will operate effectively for years if they are kept clean, dry and properly lubricated. An excessive running current is a good indication of the overall condition of the motor. Check the following items every six months (unless otherwise indicated) for proper performance:

• Motors must be cleaned with moderate air pressure (around 25 to 30 psi). Dirt must be blown away from vent ﬁns and all other accessible areas. All areas surrounding the motor must be kept clear so air can circulate freely to cool the motor.

• Ensure all connections are secure. Look for loose wires and loose contacts. Repair and tighten any defective connection.

• Ensure the motor is operating at the current indicated on the nameplate. If not, a physical or electrical restriction is working against the motor and it must be repaired.

• Ensure the motor is not vibrating too much. A signiﬁcant vibration can come from a loose mounting bolt or an unbalanced impeller. If signiﬁcant vibration has occurred, be sure to repair it and inspect the mounting base and the ﬂexible duct connection for any damage.

• Motor lubrication must occur once a year when grease nipples are provided with a premium quality lithium based grease conforming to NLGI Grade 2 or 3 (examples are Mobile AW2, Chevron Amolith#2, Texaco Premium RB, Shell Alvania #2 or ESSO Beacon #325). Clean the grease nipple ﬁrst, then rotate the motor shaft slowly by hand while adding grease. Do

not over lubricate.

Filters

Standard 2” [51 mm] ﬁlters are disposable and should be replaced every three months, sooner if pressure drop across the ﬁlters is too great. High efﬁciency ﬁlters (optional) should be replaced when dirty. Use only in combination with 2” [51 mm] ﬁlters to protect them.

The tables in Appendix N provide data relative to the pressure drop across clean ﬁlters and indicate the type of read-

Dirt on the surface of the coil reduces its ability to transfer heat which lowers the efﬁciency of the unit, resulting in poor air quality and expensive operating costs. Because of the condensate on the coil, the dirt often becomes wet and contributes to the growth of microbial organisms. Negligence in maintenance may result in serious health related indoor air quality problems.

The coil should be kept clean for maximum performance. To achieve maximum efﬁciency, clean the coil often during periods of high demand or when dirty conditions prevail. Venmar CES recommends cleaning the coil a minimum of once per year to prevent dirt buildup in the coil ﬁns where it may not be visible.

ing that should be given on the magnehelic gauge. The data relative to accurate pressure drop across the ﬁlters is available in the submittal. If the system is equipped with both preﬁlters and ﬁnal ﬁlters, it is recommended that preﬁlters be changed twice as often as ﬁnal ﬁlters. Running a unit with dirty and inefﬁcient ﬁlters will lower the airﬂow and thus lower the air quality of the area.

Coils

CAUTION

Do not use acidic chemical coil cleaners. Do not use alkaline chemical coil cleaners with a pH value greater than

8.5 or lower than 6 (after mixing) without using an aluminum corrosion inhibitor in the cleaning solution. Using these types of cleaners may result in unit damage.

Coil ﬁns can be cleaned by using steam with detergent, hot water spray or a commercial chemical coil cleaner. After cleaning the coil, be sure to rinse thoroughly.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 40

WARNING

Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

Cleaning Procedure

1. Shut down the unit by closing the main disconnect at the power inlet.

2. Open panels or doors to gain access to both sides of the coil section.

3. Remove soft debris from both sides of the coil with a soft brush.

4. Using a steam cleaning machine, clean the leaving airside of the coil ﬁrst (going downward) then clean the entering airside. Use a block-off to prevent the steam from penetrating a dry section of the unit.

5. Allow the unit to dry thoroughly before restoring power.

6. Damaged coil ﬁns (excluding brazed aluminum) should be straightened by using a ﬁn comb (not applicable to brazed aluminum heat exchangers).

7. Close all panels and doors once the coil is dry.

8. Restore electrical power to the unit.

Controls

General controls information regarding the navigation and monitoring of your unit with the standard keypad, DDC points list, ladder diagram and speciﬁc sequence of operation or required network communication is included in the

Troubleshooting

See Appendix O for troubleshooting information. For troubleshooting information on WSHP, compressors and refrigeration circuits, see Appendix B; for gas-ﬁred furnace

documentation in the control panel of your unit. Please contact the factory if this information is missing or has been lost.

modules see Appendix D; and for electric heating coils, see

Appendix G.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 41

Appendix A: Roofcurb Generic Assembly Instructions

Wood nailer

Mineral wool Mineral wool

2”

Standard design

2”

Standard design

With wood nailer option

nailer option

With wood

Detail C

Figure A1: Roofcurb assembly – EnergyPack®, ERV5000–10000, HRV3000–10000 (outdoor units only)

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Detail A Detail B

Page 42

Appendix B: Water Source Heat Pump (WSHP) Piping,

Installation, Maintenance and Troubleshooting

Units have the WSHP supply and return line connections for each compressor condenser set piped to the outside on the side of the casing as standard. An optional ﬁeld cut ﬂoor chase is available as an option, in which case the pipe connections terminate inside the casing for each compressor condenser set. See the submittal drawings for number, size, location, ﬂow rate, type of ﬂuid, pressure drop information and components included and factory installed for the supply and return connections.

Water Piping Components Included

The following components are included and factory installed as standard, depending on the water conditions or options selected.

1. A three-way modulating head pressure control valve is included and factory installed in the compressor compartment to maintain stable operation of the refrigeration systems when operated on ground loop water systems when the design inlet water temperature is below 65°F in the cooling mode. A refrigerant pressure transducer is also included and factory installed in the compressor compartment on the compressor discharge, which will modulate the water ﬂow to the condenser using a 2 to 10 VDC signal to prevent the compressor discharge pressure from falling below the compressor operating limit.

2. A ﬂow switch on the water return or leaving side of the condenser is factory provided and installed in the compressor compartment to monitor the presence or absence of ﬂow, which will shut down the compressor and unit if no ﬂow is detected.

3. A water temperature sensor on the water return or leaving side of the condenser is factory provided and installed in the compressor compartment on 100% water systems to monitor the water temperature, which will shut down the compressor and unit for freeze protection if the leaving water temperature drops below 35°F.

4. An airside economizer coil, a three-way modulating water economizer valve and a temperature sensor are included with the WSHP WiSE coil option and factory installed in the compressor compartment on the water inlet or supply line and downstream of the economizer coil for energy conservation. The water temperature sensor is input to the DDC control system, which determines when to divert water to the economizer coil for energy conservation in cooling mode.

Water Piping Components Not Included

Vibration eliminators, manual or automatic shut-off valves, pressure and temperature gauges, water strainer, vent valves or air vents, ﬂow measuring and balancing valves, pressure relief valves or other safety or control piping requirements are not provided as standard and must be ﬁeld

provided and installed outside of the unit. These components and installation are available as an option. See the piping schematic and submittal drawings for information on optional piping components when provided.

IMPORTANT

WSHP external water supply and return piping shall be in accordance with National and Local Codes. Line sizing, pressure limiting devices, back ﬂow preventers, strainers, valves, ﬂow temperature and pressure measuring, freeze protection, all other safety or control piping requirements for system operation are the sole responsibility of the Installing Contractor and/or Design Engineer. The water supply must be sized for the maximum ﬂow as indicated on the submittals.

Recommended Piping, Components and Installation

Recommended and required WSHP water line piping and components with a detailed functional description are outlined below:

1. All WSHP should be connected to supply and return piping in a two-pipe reverse return conﬁguration. A reverse return system is inherently self-balancing and requires only trim balancing where multiple quantities of heat pumps with different ﬂow and pressure drop characteristics exist in the same loop.

2. The water line piping may be steel, copper or PVC. Avoid dissimilar metal ﬁttings as they may corrode. The piping should be installed with a minimum number of bends and elevation changes for best performances. Size piping to minimize system pressure drop.

3. Water line piping should contain: a. Short sections of high pressure ﬂexible hose or vi-

bration eliminators to reduce vibration and noise transmission .One end of the hose should have a swivel ﬁtting to facilitate removal for service. Hard piping connections are not recommended due to the possibility of vibration that could damage piping connections, joints or transmit noise. Where hard piping is used, unions should be provided in the supply and return lines for service and removal.

b. Manual shut-off valves in supply and return

water lines for isolation and service.

c. Pressure and temperature gauge connections in

the supply and return water lines to aid in startup and service.

d. A water strainer (16–20 mesh minimum) or some

means of removing foreign matter from the water.

e. Manual vent valves and/or automatic air vents at

the high points of the system in the supply and return water lines to discharge non-condensable

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 43

air in order to avoid unexpected high head pres-

sure and poor cooling/heating performance.

f. A ﬂow balancing valve in the return water line to

set the required ﬂow rate.

g. A ﬂow measuring valve or pressure gauge/con-

nections in the return water line to measure the required ﬂow rate.

h. A two-way motorized on/off water shut-off valve

to isolate water ﬂowing through both the economizer coil (if equipped) and water-to-refrigerant condenser for conservation when the unit is off. The motorized water valve must open 90 seconds prior to compressor start-up and remain open ﬁve seconds after the compressor is shut off.

i. A relief valve in the water supply or inlet line if

the maximum pressure of components is less than the water supply pressure to prevent damage, injury or death due to instantaneous release of high pressure water.

WARNING

To prevent injury or death due to instantaneous release of high pressure water, provide relief valves on system water piping. This will also help prevent water pump damage or stoppage due to excessive system pressure.

4. WSHP should not be connected to the incoming supply and return piping until the water supply system has been cleaned and ﬂushed completely. After the cleaning and ﬂushing has taken place, the initial connection should have all valves wide open in preparation for the water system ﬂushing.

5. Automatic ﬂow controlled devices must not be installed prior to system cleaning and ﬂushing.

Cleaning and Flushing

1. Prior to ﬁrst operation of the WSHP, the water circulation system must be cleaned and ﬂushed of all construction dirt and debris by the Installing Contractor.

2. Short circuit connect the incoming supply line to the outgoing return line, prior to the factory installed piping at each connection point, before ﬂushing to prevent the introduction of dirt into the unit from the supply line completed on site. This will prevent the introduction of dirt into the unit.

3. Fill the system at the city water make-up connection with all air vents open. After ﬁlling, close all air vents.

4. Start the main circulator with the pressure reducing valve open. Check vents in sequence to bleed off any trapped air to provide circulation through all components of the system.

5. While circulating water, check and repair any leaks in the piping. Drains at the lowest point(s) in the system should be opened for the initial ﬂush and blow down, making sure city water ﬁll valves are set to

make-up water at the same rate. Check the pressure gauge at the pump suction and manually adjust the make-up to hold the same positive steady pressure both before and after opening the drain valves. Flush should continue for at least two hours or longer until clean drain water is visible.

6. Shut off the circulator pump and open all drains and vents to completely drain down the system. Short circuited supply and return lines coming to the unit should now be removed and supply and return lines connected to the unit supply and return connections. Do not use sealers at the swivel ﬂare connections of the hose(s).

7. Install any automatic ﬂow controlled devices that were removed for ﬂushing.

8. Reﬁll the system with clean water. Test the water using litmus paper for acidity, and treat as required to leave the water slightly alkaline (pH 7.5 to 8.5). Note that during equipment functional testing, the factory utilizes a mixture of 50% propylene glycol and 50% water. Traces of propylene glycol/water mixture may still be present in the equipment water system and may require a complete water system ﬂush in 100% critical water applications. The speciﬁed percentage of antifreeze may also be added at this time. Use commercial grade antifreeze designed for HVAC systems only. Do not use automotive grade antifreeze.

9. Once the system has been ﬁlled with clean water and antifreeze (if used), precaution should be taken to protect the system for dirty water conditions. Dirty water will result in system wide degradation of performance and solids may clog valves, strainers, ﬂow regulators, etc. Additionally, the heat exchangers may become clogged which reduces compressor service life or causes premature failure.

CAUTION

Units with WSHP installed outdoors must be protected from freezing temperatures to prevent severe damage to components.

10. Start the circulation pumps. After full ﬂow has been established though all components, air vented, lines checked for leaks and loop temperatures stabilized, the WSHP will be ready for check, start-up and water balancing.

General Maintenance

Recording of performance measurements of volts, amps, and water temperature difference (both heating and cooling) is recommended. A comparison of logged data with start-up and other annual data is useful as an indicator of general equipment condition.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 44

Periodic lockouts almost always are caused by air or water problems. The lockout (shut down) of the unit is a normal protective result. Check for dirt in the water system, water ﬂow rates, water temperatures, airﬂow rates (may be dirty ﬁlters), and air temperatures. If the lockout occurs in the morning following a return from the night setback, entering air below machine limits may be the cause.

Water treatment is important for proper condenser operation. More frequent cleaning will be necessary if water is not properly treated. For water treatment instruction, consult your local water treatment specialist.

WSHP units are designed for failsafe to heating.

Monthly

• Check condenser coil for scaling.

Quarterly

• Check oil level in compressor (half site glass).

Semi-annually

• Check operation of crank case heaters.

• Check for broken or loose pipe clamps.

• Check moisture indicator of refrigerant site glass. A ‘Caution’ or ‘Wet’ condition requires changing ﬁlter drier. If ‘Wet’ condition does not improve, it will be necessary to evacuate system.

Yearly

• Look for any sign of oil on all refrigeration components including coils, compressors, controls, tubing, etc. Oil would indicate a refrigerant leak.

• Check water lines for leaks.

• Check expansion valve bulb (properly attached to suction line, properly isolated).

• Check the condensate drain pan and clean and ﬂush as required.

Troubleshooting

Lubrication

R410a should be used only with polyolester (POE) oil. The HFC refrigerant components in R410a will not be compatible with mineral oil or alkylbenzene lubricants. R410a systems will be charged with the OEM recommended lubricant, ready for use with R410a.

Charging

Due to the zeotropic nature of R410a, it should be charged as a liquid. In situations where vapor is normally charged into a system, a valve should be installed in the charging line to ﬂash the liquid to vapor while charging.

CAUTION

It is very important to make certain that the recycle or recovery equipment used is designed for R410a. The pressure of R410a refrigerant is approximately 60% greater than that of R22. Pressure gauges require a range up to 800 psig high side and 250 psig low side. Recovery cylinders require a 400 psig rating.

IMPORTANT

Filter driers must be replaced each time a system is open to atmosphere (i.e. for a defective component replacement, refrigerant leak, etc.).

Compressor burnout

When a motor burnout occurs in a compressor, the resulting high temperature arc causes a portion of the refrigerant/oil mixture to break down into carbonaceous sludge, corrosive acid and water.

Such contamination resulting from a burnout can result in repeat failures if the contaminants are allowed to reach and remain in the crank case of the replacement compressor. This situation can be prevented by following proper cleanup procedures after a burnout.

To determine if a compressor burnout has actually occurred, run the proper electrical tests. This requires an accurate VOM Meter.

1. With all wires removed from the compressor terminals, measure resistance from each terminal to the compressor casing. If any terminal shows a direct ground (zero resistance), a failure has occurred. If not, continue.

2. With all wires removed from the compressor terminals, measure resistance from each compressor terminal. They should read the same. If two or more terminals show zero resistance between them, the compressor motor has failed (for actual resistance value, refer to the respective compressor manual or contact the service department at Venmar CES).

3. If Steps 1 and 2 have not clearly identiﬁed a compressor failure, it will be necessary to meg the compressor motor (refer to the respective compressor manual or contact the service department at Venmar CES).

Compressor Burnout – System Cleanup

Any maintenance requiring refrigerant evacuation must be performed using proper recovery procedures.

1. In order to avoid losing refrigerant to the atmosphere, recover refrigerant using standard recovery procedures and equipment. Remove the inoperative compressor and install the replacement.

2. Since the normal color of refrigerant oil varies from oil to oil, take a sample of oil from the replacement compressor and seal in a small glass bottle for com-

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 45

parison purposes after the cleaning operation is com-

plete. Suitable 2 ounce bottles are available at any drug store.

WARNING

3. Inspect all system controls such as expansion valves, solenoid valves, check valves, reversing valves, contactors, etc. Clean or replace if necessary, remove all installed ﬁlter driers.

IMPORTANT

Before starting the new compressor, replace any questionable component.

4. Install the recommended size suction line ﬁlter drier and new size liquid line ﬁlter drier. Evacuate system using the triple evacuation method. Re-charge the system with new refrigerant (do not use the recovered refrigerant). See unit’s nameplate for proper refrigerant charge.

5. Start the compressor and put the system in operation. As the contaminants in the system are ﬁltered out, the pressure drop across the suction line ﬁlter drier will increase. Observe the differential across the

ﬁlter drier for a minimum of two hours. If the pressure drop exceeds the maximum limits for a temporary installation, replace the ﬁlter drier and restart the system (see literature from ﬁlter drier’s manufacturer for pressure drop maximum limits).

6. After the completion of Step 5, allow the unit to operate for 48 hours. Check the odour (warning – smell cautiously) and compare the color of the oil with the sample taken in Step 2. Use of an Acid Test Kit is recommended to test for acid content. If the oil is discolored, has an acid odour, is acidic, or if the moisture indicator indicates a high moisture content in the system, change the ﬁlter driers. The compressor oil can be changed if considered desirable. Allow the system to operate for an additional four hours and recheck as before. Repeat until the oil remains clean, odour and acid free and the color approaches that of the original sample.

7. Replace the liquid line ﬁlter drier with one of the normally recommended size. Remove the suction line ﬁlter drier.

8. After the cleaning procedure is completed, re-check in approximately two weeks to ensure that the system condition and operation is completely satisfactory.

Table B1: Troubleshooting Refrigeration Circuit

Symptom

Undercharged system (possible leak)

Overcharged system High High High Normal High

Low airﬂow heating High High High

Low airﬂow cooling Low Low Low

Low water ﬂow heating Low water ﬂow cooling

High airﬂow heating Low Low Low Low High Low Low

High airﬂow cooling Low High Normal High Low Low Normal High pressure High water ﬂow

heating High water ﬂow cooling

TXV restricted High Low

Head Pressure

Low Low Low High Low Low Low Low pressure

Low

Normal

High High High High Low Low High High pressure

Normal Low Low Low Normal Normal Low High pressure

Low Low Low Low High Normal Low

Suction Pressure

Low

Normal

Compressor Amp Draw

Low Low High Low High

Normal

Superheat Subcooling

High

Normal

Low

Normal

High High Low Low

Low

Low High Low High pressure

Low Low Low

Air Temperature Differential

Normal

Water (Loops) Temperature Differential

Normal High pressure

Low

Safety Lockout

Low temperature Low temperature

Low temperature

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 46

Table B2: Performance Troubleshooting

Performance Troubleshooting

Heating Cooling Possible Cause Solution

Insufﬁcient capacity. x x Dirty ﬁlter. Replace or clean.

Check for dirty air ﬁlter and clean or replace. Check

x Reduced or no airﬂow.

fan motor operation and airﬂow restriction. Too high of external static. Check static vs. blower performance curve.

Not cooling or heating properly.

x Reduced or no airﬂow.

Check for dirty air ﬁlter and clean or replace. Check fan motor operation and airﬂow restriction. Too high of external static. Check static vs. blower performance curve. Check supply and return air temperature at the unit

x x Leaky ductwork.

and at the distant duct registers. If signiﬁcantly different, duct leaks are present.

x x Low refrigerant charge. Check superheat and subcooling; adjust charge. x x Restricted metering device. Check superheat and subcooling; replace TXV.

Unit does not operate in cooling.

x x Unit undersized. Re-check loads and sizing.

x x

x Defective reversing valve. Perform reversing valve touch test.

Scaling in waterside heat exchanger.

Perform scaling check and clean if necessary.

x x Inlet water too hot or too cold. Check load, loop sizing, loop backﬁll, ground moisture.

Check for dirty air ﬁlter and clean or replace. Check

x Reduced or no airﬂow.

fan motor operation and airﬂow restriction. Too high of external static. Check static vs. blower performance curve. Check pump operation or valve operation/setting. Check water ﬂow. Adjust to proper ﬂow rate.

High head pressure.

x Reduced or no water ﬂow.

x Inlet water too hot. Check load, loop sizing, loop backﬁll, ground moisture.

x Air temperature out of range. Bring return air temperature within design parameters.

Scaling in waterside heat

exchanger.

Perform scaling check and clean if necessary.

x x Unit overcharged. Check superheat and subcooling. x x Non-condensable in system. Vacuum system, re-weigh in charge.

x Reduced water ﬂow.

Check pump operation or valve operation/setting. Check water ﬂow. Adjust to proper ﬂow rate.

x Water temperature out of range. Bring water temperature within design parameters.

Check for dirty air ﬁlter and clean or replace. Check

Low suction pressure.

x Reduced airﬂow in cooling.

fan motor operation and airﬂow restriction. Too high of external static. Check static vs. blower performance curve.

x Air temperature out of range. Bring entering air temperature within design parameters.

x x Insufﬁcient charge. Check for refrigerant leaks.

Low discharge air temperature in heating.

x Too high of airﬂow. Check fan’s motor speed selection and airﬂow. x Poor performance. See insufﬁcient capacity.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 47

Appendix C: Positive and Negative Pressure Trapping

H = 1” [36 mm] (for each 1“ [25 mm] of maximum negative static pressure) + 1” [25 mm] J = Half of H X = 3.9375” [100 mm] if unit has a 6” [152 mm] tubular steel base L = H + J + pipe diameter + insulation − X

Removable plug

Cleanout

Removable plug

Cleanout

K = Minimum 0.5” [13 mm] H = 0.5” [13 mm] + maximum total static pressure X = 3.9375” [100 mm] if unit has a 6” [152 mm] tubular steel base L = H + K + pipe diameter + insulation − X

Figure C1: Positive pressure trapping

Figure C2: Negative pressure trapping

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 48

Appendix D: Gas-ﬁred Furnace Modules Installation and Maintenance

Tubular Gas-ﬁred Duct Furnace Module

WARNING

Fire or explosion hazard

1. Failure to follow safety warnings exactly could cause serious injury, death or property damage.

2. Be sure to read and understand the installation, operating and maintenance instructions in this appendix thoroughly before installing or servicing this equipment.

3. Improper installation, adjustment, alteration, service or maintenance can cause serious injury, death or property damage.

4. Do not store or use gasoline or other ﬂammable vapors or liquids in the vicinity of this or any other appliance.

For your safety – What to do if you smell gas

1. Open windows if appliance is indoors.

2. Do not try to light any appliance.

3. Do not touch electrical switches or use any phone in the building.

4. Extinguish any open ﬂame.

5. Leave the building immediately.

6. Immediately call your gas supplier from a phone remote from the building. Follow the gas supplier’s instructions.

7. If you cannot reach your gas supplier, call the ﬁre department.

Installation and service

1. Installation and service must be performed by a qualiﬁed installer, service agency or the gas supplier.

The furnace covered by this appendix is a component of a “Listed” product, subject to the guidelines of application as designated by the Certifying Agency and outlined in the appliance Manufacturer’s installation and operation instructions.

2. Do not install the appliance where it may be exposed to potentially explosive or hazardous atmospheres containing ﬂammable vapors or combustible dust.

3. Do not locate the appliance in areas or near building ventilators or exhausts where corrosive vapors (such as chlorinated, halogenated or acidic or airborne substances containing silicone) are present in the atmosphere or can be mixed with combustion air entering the furnace module.

4. Do not install the appliance in locations where ﬂue products can be drawn in the adjacent building openings such as windows, fresh air intakes, etc.

5. The appliance is not certiﬁed or suitable for use in drying or process applications. Units used in such applications voids any warranty and Manufacturer disclaims any responsibility for this appliance or application.

6. If any original wire supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 104°F [90°C].

7. Provide necessary support for wiring in furnace vestibule. Wiring should not contact metal surfaces that may be hot during furnace module operation.

Installation

IMPORTANT

All gas furnace installations must be in accordance with the National Fuel Gas Code ANSA Z223.1 (NFPA 54) in the United States, to the Gas Installation Code Can/CGA B149 in Canada and all other applicable local codes and ordinances. These requirements include but are not limited to:

1. Combustion air supply to the gas furnace

2. Venting of the products of combustion

3. Gas supply piping and connections

4. Unit location and clearances

The information provided in this appendix applies to the furnace module, installed in the appliance and to its operation, maintenance and service. Refer to the appliance Manufacturer’s instructions for information related to all other components.

IMPORTANT

Combustion air intake and vent locations differ; see submittal drawings for actual locations.

Installation Requirements

1. Be sure that the unit is located with respect to building construction and other equipment to provide ready access and clearance to access panels or doors that must be opened to permit adjustment and servicing of the heating section. See the required clearances provided on the mechanical drawing.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Verify the following before placing the gas furnace into service:

1. Gas supply provided matches the gas type marked on the furnace module rating plate, the gas supply line has been completed according to the Gas Sup-

ply, Piping and Connections section and has been

cleaned, drained and purged to the external manual shut-off valve.

2. There is an adequate supply of air for the combustion process for the furnace module according to the type of installation.

3. There is a properly designed vent system connected to the furnace module to convey the products of combustion (ﬂue gases) outdoors and are directed away from any combustion air intakes according to the installation.

Page 49

Outdoor Installation

Flue gas chimney

(standard on outdoor)

Flue gas flow unobstructed

Comb

Blwr

AHU

cabinet

AHU

cabinet

Combustion air inlet hoods

Air for Combustion

The furnace is power vented with a combustion air draft inducer/blower and needs an ample supply of air for proper and safe combustion of the fuel gas. Combustion air inlet hoods are provided in the panel on the furnace vestibule. Do not block or obstruct air openings to the area where the appliance is installed. Provide at least 6 feet [1,829 mm] clearance to side of the appliance, where the combustion air inlet or vent (ﬂue) gas discharge is located, from walls, parapets or adjacent buildings or equipment. Do not locate appliance near building ventilators or exhausts, or areas where corrosive chemical vapors can be drawn into combustion air supply. Refer to appropriate installation codes for required clearances to combustion air openings and ﬂue gas (vent) outlets.

Venting

The venting system for outdoor appliances is a Category III, with the vent products at positive pressure and up to 550°F [288°C]. Each furnace must be individually vented. The venting system is designed for horizontal direct discharge to the exterior of the cabinet and provided with factory built individual vertical exterior double wall vent stacks that extend above the top of the appliance by a minimum of 1 to 2 feet [302 to 604 mm], providing a minimum 4 foot [1,016 mm] separation between ﬂue gas discharge and combustion air inlet. A ½” drain ﬁtting is provided in the bottom of the stack permitting condensate that may form to drain through. The vent stacks are open at top but protected by ½” x ½” [12 x 12 mm] mesh screens. The vent discharge opening should be located to provide an unobstructed discharge to the outside (see Figure D1).

Figure D1: Typical outdoor vertical venting

Where sufﬁcient height for proper vertical venting must be greater or in jurisdictions requiring a greater separation between ﬂue gas discharge and combustion air inlet the vent stacks provided with the unit must be replaced by separate self-supported factory built closed chimneys or vents complying with a recognized standard to Category III with a 90° elbow and a ﬁeld supplied transition. The closed venting system must employ a drain line in the vent chimney and an approved rainproof vent cap must be applied to the termination.

The proper vent pipe diameter must be used for each furnace to ensure proper venting of combustion products. See Table D1 for required furnace vent size and submittal for number of furnaces and Btuh input rating.

Indoor Installation

Air for Combustion

Locate appliance to ensure an adequate supply of fresh air to replace air used in the combustion and ventilation process of the furnace module. The appliance must be installed in a location with adequate clearances to provide for an adequate combustion air space, service and inspection and proper clearances from combustible construction. The appliance must be located in such a manner that it does not interfere with the circulation of air in the heated space.

All fuel burning equipment must be supplied with air that enters into the combustion process and is then vented outdoors. Combustion air inlet hoods are provided in the panel on the furnace vestibule. Sufﬁcient air must enter the appliance location to replace the air exhausted through the vent system. Do not install appliance in a conﬁned space without providing wall openings to and from this space. If building construction is such that the normal inﬁltration does not provide sufﬁcient air for combustion and venting, outside air must be introduced. Install air openings that provide a total free area in accordance with following and to the National Fuel Gas Code Z223.1 (NFPA 54) in the US or in Canada, to the Can/CGA-B149 Installation Code:

1. Air from inside the building – Opening of 1 sq. inch [645 mm2] per 1,000 Btuh [293 W] of input, but never less than 100 sq. inch [0.06 m2].

2. Air from outside (ducted) – Opening of 1 sq. inch [645 mm

3. Air from outside (direct opening) – Opening of 1 sq. inch [645 mm2] per 4,000 Btuh [1,172 W].

As an option, a combustion air opening of proper size can be provided in the furnace enclosure and ducted directly to outdoors. See Separated Combustion Air Intake System for further details.

] per 2,000 Btuh [586 W].

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 50

Venting

Roof line

Exhaust vent

terminal

Air inlet

Tee fitting with drip leg and cleanout cap

¼” [6 mm] per

1 foot [305 mm]

A = 10” [3.05 m] maximum horizontal run (not to exceed 75% of vertical run) B = 2 ft [0.61 m]

Exhaust

Each furnace must be connected to a venting system to convey ﬂue gases outside of the heated space. Refer to installation codes noted above for speciﬁc requirements for the product type being installed.

The induced draft fan rectangular vent connection for each furnace is factory ﬁtted with a rectangular to round transition and run to the side of the furnace vestibule.

Each furnace must be connected to a separate factory built chimney or vent complying with a recognized standard or a masonry or concrete chimney lined with a material acceptable to the authority having jurisdiction.

7. Dampers must not be used in vent piping runs. Spillage of ﬂue gases into the occupied space could result.

8. Vent connectors serving Category I heaters must not be connected into any portion of a mechanical draft system operating under positive pressure.

Table D1: Furnace, Vent Connection Size and Vent Pipe Diameter

Input Rating Btuh [Watts]

100,000–125,000

[29,307–36,634] 200,000–400,000 [58,614–117,228]

Vent

Connection

Diameter

5” [127 mm] 5” [127 mm]

6” [152 mm] 6” [152 mm]

Vertically Vented Furnaces (see Figure D2) – Category I (per NFGC and ANSI Z21.13 is a non-condensing appliance with negative vent pressure)

1. Use single wall or double wall (Type B) vent pipe diameters for the appropriate models. Use insulated vent outdoors.

2. Maximize the height of the vertical run of vent pipe. A minimum of 5 feet [1.5 m] of vertical pipe is required. The top of the vent pipe must extend at least 2 feet [0.61 m] above the highest point on the roof. Use Listed Type B vent for external runs.

3. An approved weatherproof vent cap must be installed to the vent termination.

4. Horizontal runs must not exceed 75% of the vertical height of the vent pipe, up to a maximum of 10 feet [3 m]. Horizontal runs should be pitched upward ¼ inch per foot [21 mm/m] and should be supported at 3 foot [1 m] maximum intervals.

5. Design vent pipe runs to minimize the use of elbows. Each 90° elbow is equivalent to 5 feet [1.5 m] of straight vent pipe run.

6. Vent pipe should not be run through unheated spaces. If such runs cannot be avoided, insulate vent pipe to prevent condensation inside vent pipe. Insulation should be a minimum of ½” [12.7 mm] thick, foil faced material suitable for temperatures up to 500°F.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Vent Pipe Diameter

Figure D2: Indoor vertical venting

Horizontally Vented Furnaces (see Figure D3) – Category III (Per NFGC and ANSI Z21.13 is positive vent pressure and non-condensing)

Pressures in Category III venting systems are positive and therefore, care must be taken to avoid ﬂue products from entering the heated space. Use only vent materials and components that are UL listed and approved for Category III venting systems.

WARNING

Do not use Type B vent within a building on horizontally vented indoor furnaces.

1. All vent pipe joints must be sealed to prevent leakage into the heated space. Follow instruction provided with approved venting materials used.

2. The total equivalent length of vent pipe must not exceed 50 feet [15.35 m]. Equivalent length is the total length of straight sections, plus 5 feet [1.52 m] for each 90° elbow and 2.5 feet [0.76 m] for each 45° elbow.

3. The vent system must also be installed to prevent collection of condensate. Pitch horizontal pipe runs downward ¼ inch per foot [21 mm/m] toward the outlet to permit condensate drainage. Insulate vent pipe exposed to cold air or routed through unheated areas. Insulate vent pipe runs longer than 10 feet [3 m]. Insulation should be a minimum of ½” [12 mm] thick foil faced material suitable for temperatures up to 500°F [288°C]. Maintain 6” [152 mm] clearance between vent pipe and combustible materials.

4. A vent cap approved for horizontal venting must be provided. Vent cap inlet diameter must be the same

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as the required vent pipe diameter. The vent termi-

Exterior wall

terminal

nal must be at least 12” [305 mm] from the exterior wall that it passes through to prevent degradation of building material by ﬂue gases. The vent terminal must be located at least 1 foot [305 mm] above grade, or in snow areas, at least 3 feet [1 m] above snow line to prevent blockage. Additionally, the vent terminal must be installed with a minimum horizontal clearance of 4 feet [1.2 m] from electric meters, gas meters, regulators or relief equipment. Periodically clean the screens in the vent terminal (where applicable).

IMPORTANT

Each furnace must have its own individual vent pipe and terminal. Do not connect vent system from horizontally vented units to other vent systems or a chimney.

5. Through the wall vents shall not terminate over public walkways, or over an area where condensate or vapor could create a nuisance or hazard. Provide a vent termination clearance to building or structure features per Table D2.

Table D2: Vent Termination Clearances

Structure Minimum Clearance

4 ft. [1.2 m] below

Door, window or gravity inlet

Forced air inlet within 10 ft. [3 m] 3 ft. [0.91 m] above

Adjoining building or parapet 6 ft. [1.8 m]

Adjacent public walkways 7 ft. [2.1 m] above grade

A = 12” minimum

4 ft. [1.2 m] horizontally

1 ft. [305 mm] above

Separated Combustion Air Intake Systems

On indoor units for operation with separated combustion air intake systems, the burner section is in a reasonably air-tight vestibule compartment, as these systems provide combustion air from outside the heated space and vent the products of combustion outdoors. No air openings are to be made in the vestibule to maintain a reasonably airtight seal. Additionally the unit must include the following:

1. A suitable air-tight gasket on the vestibule door or access panel.

2. An observation window in the door to permit observation of ignition and main burner ﬂame during operation and servicing.

3. A door or panel interlock switch to ensure that door or panel is closed or in place during operation.

4. The induced draft fan rectangular vent connection for each furnace is factory ﬁtted with a rectangular to round transition and run to the side of the furnace vestibule.

5. A single combustion air inlet supply duct connection is provided in the furnace vestibule for the number of furnaces provided. See submittal drawings for location, size and number.

Proper installation of combustion air intake and ﬂue gas exhaust piping are essential to proper operation of the inshot gas burner module. See Figure D4 and Figure D5 for recommended installation.

IMPORTANT

Approved combustion supply air intake and exhaust ﬂue gas vent piping and terminals must be used between the unit and outdoors for combustion supply air and exhaust ﬂue gas. The inlet and outlet terminals must be located in the same outdoor pressure zone to provide for safe appliance operation.

6 ft. [1.8 m] min.

to wall or

adjoining building

Exhaust vent

Approved vent caps

Combustion air inlet

Exhaust

Air inlet

Tee fitting

with drip leg

Pitch vent pipe

downward from

furnace ¼ inch

per foot

Figure D3: Indoor horizontal venting

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Exhaust vent

2.5 ft. [0.75 m] min.

12” [0.3 m] min.

Exhaust

Heating appliance

18” [0.46 m] min. * (See note)

Tee with drip leg and cleanout cap

18” [0.46 m] min.

* Provides sufficient height to exceed expected snow depth

Figure D4: Separated combustion – vertical venting

Page 52

5 ft. [1.5 m] min.

25 ft. [15.2 m] max. equivalent length

Pitch pipes down ¼ in./ft [21 mm/m] toward terminal caps to allow for condensate drainage

12” [0.3 m]

18” [0.46 m]

min. @ CL

Note: Be sure that the vent cap used for horizontal venting applications is approved for horizontal application. Certain Manufacturer’s vent terminals are approved for vertical installation only.

3 ft. [0.9 m] min.

Exhaust vent

Combustion air inlet

24”

[0.6 m]

Building overhang

6 ft. [1.8 m]

min.

3 ft. [0.9 m] min. above grade or expected snow depth

Adjacent building

Figure D5: Separated combustion – horizontal venting

Gas Supply, Piping and Connections

1. All gas piping must conform with local building codes and ordinances or, in the absence of local codes, with ANSI Z223.1 the National Fuel Gas Code and NFPA 54 in the US. In Canada, installation must be in accordance with Can/CGA B149.1 for natural gas and B149.2 for propane units.

2. Gas piping must be sized for the total Btuh input of the appliance serviced by a single supply line. Refer to the number of furnace(s) and the total input of their rating plate(s). Each furnace has a ¾” NPT piping connection extended to the exterior of the cabinet. The gas supply line feeding more than one furnace must be checked for size relative to the connection at each furnace to maintain minimum required pressure to each furnace.

3. A drip leg (sediment trap) and a manual gas shut-off valve must be ﬁeld supplied and installed immediately adjacent to the point where the gas supply line enters the cabinet. To facilitate servicing, installation of a union is recommended (see Figure D6). The appliance must be isolated from the gas supply system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures greater than 13.5” w.c. [½ psi]. Always use clean, scale-free pipe and malleable iron ﬁttings, and remove all cutting and threading debris prior to connecting pipes. Firmly support the gas piping so that it cannot be dislodged from its installed position.

Gas supply line

Manual gas

Gas supply line

3” min.

Sediment trap

shut-off valve

Figure D6: Union installation

Plugged 1/8” NPT test gauge connection

Ground joint union with brass seat

To controls

4. For the furnace(s) to operate properly, the minimum inlet gas supply pressure to each furnace for natural gas operation is 5.0” w.c. and for propane (LP) gas is

11.0” w.c. with the furnace(s) operating. Maximum inlet pressure for either gas is 13.5” w.c. [½ psi]. For higher gas pressures, a separate ﬁeld supplied and installed high pressure regulator sized for the total Btuh input is required to reduce pressure to within minimum and maximum range. The high pressure regulator used must include full internal relief or a separate relief valve is required to prevent gas pressure exceeding the maximum 13.5” w.c. [½ psi] limit to prevent damage to the furnace gas valve(s).

5. A 1/8” NPT tap is provided on the inlet of the gas valve to each furnace. A ﬁtting suitable for connection to a pressure gauge capable of measuring gas pressure should be connected to each furnace. Check gas inlet pressure at each furnace with all of the furnaces operating at the same time. See Figure D7.

Min. 5.0” w.c. natural gas Min. 11.0” w.c. propane gas

Gas

supply

Pressure

regulator

Max. 13.5” w.c.

Unit 1Unit

nit 3

Figure D7: Gas piping line, regulator and over pressure relief valve must be sized to be within the minimum and maximum pressure ratings of all furnaces or appliances serviced.

WARNING

1. All ﬁeld gas piping must be pressure/leak tested prior to operation. Never use an open ﬂame to check for leaks. Use a soap solution or other leak detecting solution for testing.

2. Gas pressure to appliance controls must never exceed 13.5” w.c. [½ psi].

WARNING

1. When pressure testing at ½ psi or less, close the manual shut-off valve on the appliance before testing.

2. When pressure testing gas supply line at ½ psi or higher, close manual gas valve and disconnect heater from supply line to be tested. Cap or plug the supply line.

Airﬂow Considerations, Condensation and Full Modulation Firing Rate Control

1. Airﬂow through the furnace is dependent on the conﬁguration. See the submittal drawing for airﬂow conﬁguration through the furnace. a. For vertical downﬂow (see Figure D8). In this

conﬁguration, condensate due to operation of air conditioning system can form in the furnace tubes and would drain through the open furnace

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Page 53

tubes near the base in the furnace control ves-

tibule. A condensate drain pan should be ﬁeld provided for these applications. A condensate drain ﬁtting is provided in the ﬂue box. Some condensation may occur in the ﬂue collector box with 5:1 modulating control and a ¼” stainless steel drain line is attached to the drain ﬁtting and extended through to the outside of the furnace vestibule for each furnace.

b. For horizontal or down airﬂow through the fur-

nace, condensate due to operation of air conditioning system can form in the furnace tubes and would drain to the furnace ﬂue box. A condensate drain ﬁtting is provided in the ﬂue box. A ¼” stainless steel drain line is attached to the drain ﬁtting and extended through to the outside of the furnace vestibule for each furnace.

2. Furnaces equipped with modulating control are capable of minimum input rates as low as 20%. Below the minimum modulation rate the furnace will cycle on and off to maintain the discharge air setpoint. Consideration must be given to the vent conditions and particularly the circulating airﬂow rates to ensure that the operating air temperature rise is above the dew point temperature of the ﬂue gases in all applications and below the maximum allowable air temperature rise to limit the furnace tube temperature. The selection software limits the furnace input to be below the maximum temperature rise of 90°F [50°C]

and the discharge sensor limits the maximum supply air leaving temperature. In the event of a heat recovery failure where the furnace design temperature rise may be insufﬁcient, the low limit function will shut down the unit to reduce the possibility of condensation. Condensation of the ﬂue gas is corrosive and will result in shortened heat exchanger life and is not permitted. The materials used for furnace tubes and vent connectors are designed for non-condensing operation during the heating cycle.

3. The heat capacity of the furnace is controlled by the burner oriﬁces and the gas manifold pressure. The manifold pressure is factory set but should be checked at the time of start-up as described below. It is important not to change the design conditions or airﬂow, to measure the minimum and maximum temperature rise sufﬁciently far enough downstream (where the temperature is uniform) and make the proper adjustments.

WARNING

Operation of the furnace module at vent temperatures below that speciﬁed for a Category III could result in condensation during operating cycles causing premature failure of the vent connections or heat exchanger and hazardous operation. Operation of the furnace module above the maximum air temperature rise could result in excessive tube temperatures, premature failure and high limit switch shut down.

Figure D8: Vertical airﬂow conﬁguration

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WARNING – FOR YOUR SAFETY

The use and storage of gasoline or other ﬂammable vapors and liquids in open containers in the vicinity of this appliance is hazardous.

Operating and Safety Instructions

1. See Figure D8 for component locations.

2. This furnace module does not have a pilot. It is equipped with a direct spark ignition device that automatically lights the gas burner. Do not try to light burners by hand.

3. Before operating, leak test all gas piping up to heater gas valve. Smell around the unit area for gas. Do not attempt to place heater in operation until source of gas leak is identiﬁed and corrected.

4. Use only hand force to push and turn the gas control knob to the ‘On’ position. Never use tools. If knob does not operate by hand, replace gas valve prior to starting the unit. Forcing or attempting to repair the gas valve may result in ﬁre or explosion.

5. Do not attempt to operate unit if there is indication that any part or control has been under water. Any control or component that has been under water must be replaced prior to trying to start the unit.

Start-up

1. Turn thermostat or temperature controller to its lowest setting.

2. Turn off gas supply at the manual shut-off valve.

3. Turn off power to the appliance at the disconnect switch.

4. Remove access panel or open door to appliance vestibule housing the gas furnace.

5. Move gas control knob to ‘Off’ position. The furnace module is provided with a supply air proving interlock switch to ensure minimum supply airﬂow prior to burner operation. Set the switch after ductwork has been completed to open just below the minimum supply airﬂow on the furnace rating plate.

6. Install a tapped ﬁtting for attachment to a manometer (or other gauge suitable for 14” w.c.) in the inlet pressure tap and for 10” w.c. in the manifold pressure tap.

7. Wait ﬁve minutes for any gas to clear out. If you smell gas, see Step 2 above and correct leak. If you do not smell gas or have corrected any leaks, go to the next step.

8. Turn gas control knob to ‘On’ position.

9. Open all manual gas valves.

10. Turn power on at disconnect switch.

11. For start-up, temporarily set the DDC Control System for heating and to its highest position to initiate call for heat and maintain operation of furnace. Continue start-up following the Sequence of Operation, LED Flash Code Key and Trouble Shooting Guide for Fen-

wal 35-61 Series Direct Ignition Control based on the burner ﬁring rate control (on/off, two-stage or full modulation) and Troubleshooting Guide provided on the furnace at the end of this appendix.

12. Check and adjust manifold pressure (see Figure D9). a. The correct heat capacity of the furnace is con-

trolled by the burner oriﬁces and the gas manifold pressure. The manifold pressure is factory set but should be checked at the time of start-up as described below. For modulation control the analog input signal could also be limited by the control system depending on the airﬂow rate. See Airﬂow Considerations, Condensation and

Full Modulation Firing Rate Control above.

b. For two-stage and full modulation control systems

manifold pressure should be 1.2” w.c. for natural gas and 3.5” w.c. for propane during the 90 second warm-up period. Adjust low regulator on two-stage gas valve, if necessary. After 90 seconds, manifold pressure should increase to 3.5” w.c. for natural gas and 10.5” w.c. for propane within 30 to 45 seconds for two-stage units. For modulating units, after 90 seconds, the manifold pressure will vary depending on the analog input signal. At 10 VDC, pressure should be 3.5” w.c. for natural gas and 10.5” w.c. for propane; at 0 volts the manifold pressure should be 0.3” w.c. for natural gas and 1.1” w.c. for propane.

c. For on/off units, the manifold pressure should

be 3.5” w.c. for natural gas and 10.5” w.c. for propane.

Figure D9: Gas valve

13. Prior to completing the start-up, check the appearance of the main burner ﬂame. See Figure D10 and Figure D11 for ﬂame characteristics of properly adjusted natural gas systems. a. The burner ﬂame should be predominantly blue

in color, well deﬁned and centered at the tube entry. Distorted ﬂame, yellow tipping of natural gas ﬂame or a long yellow ﬂame on propane, may be caused by lint and dirt accumulation inside burner or at burner ports, at air inlet be-

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 55

tween burner and manifold pipe, or debris in the main burner oriﬁce. Soft brush or vacuum clean affected areas.

b. Poorly deﬁned, substantially yellow ﬂames or

ﬂames that appear lazy indicate poor air supply to burners or excessive burner input. Verify gas supply type and manifold pressure with rating plate.

c. Poor air supply can be caused by obstructions

or blockage in heat exchanger tubes or vent discharge pipe. Inspect and clean as necessary to eliminate blockage. Vacuum any dirt or loose debris. Clean heat exchanger tubes with stiff brush. Poor ﬂame characteristics can also be caused by undersized combustion air openings or ﬂue gas recirculation into combustion air supply. Increase air opening size or re-direct ﬂue products to prevent recirculation.

d. Reduced air delivery can also be the result of fan

blade slippage, dirt accumulation in the fan blade or low voltage to draft inducer motor. Inspect draft fan assembly and be sure fan blade is secure to motor shaft. Check line voltage to heater.

Shut Down

1. Set thermostat or controller to lowest setting.

2. Turn off electrical supply to unit at disconnect switch.

3. Turn off manual gas supply.

4. Disconnect manifold and inlet pressure taps and reinstall pipe plugs.

5. Replace vestibule access panel or close door.

Normal Operation

1. Turn on electrical supply to unit at disconnect switch.

2. Turn on manual gas supply.

3. Set thermostat or temperature controller to desired temperature.

4. Information outlining the normal Sequence of Operation and Wiring Diagram for the control system supplied with the furnace model is enclosed with this instruction.

Multi-purpose meter

Use microamp scale

Figure D10: Burner ﬂame at start-up 1.2” w.c. manifold pressure draft inducer – high speed

Figure D11: Burner ﬂame at high ﬁre 3.5” w.c. manifold pressure draft inducer – high speed

Red (+)

FC− FC+

Black (−)

Series 35-61 Module

Figure D12: Flame sensor current check

Fenwal Series 35-6 Ignition Control

Fault Conditions and LED Key

LED steady on Internal control fault 1 Flash Combustion airﬂow fault 2 Flashes Flame with no call for heat 3 Flashes Ignition lockout

LED ﬂashes on for ¼ second and off for ¼ second during fault condition. Pause between fault codes is three seconds.

Service Checks

Flame current is the current which passes through the ﬂame from the sensor to ground. The minimum ﬂame current necessary to keep the system from lockout is 0.7 microamps. To measure ﬂame current, connect analog DC microammeter to the FC− and FC+ terminals per Figure D12. Meter should read 0.7 uA or higher. If the meter reads below 0 on scale, meter leads are reversed. Disconnect power and reconnect meter leads for proper polarity.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

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Security Device Operation

1. A combustion air pressure switch is provided as part of the control system to verify airﬂow through draft inducer by monitoring the difference in pressure between the draft inducer and the atmosphere. If sufﬁcient negative pressure is not present, indicating lack of proper air movement through furnace heat exchanger, the switch opens shutting off gas supply through the ignition control module. On furnaces with two-speed draft inducer operation, a dual air pressure switch is used, monitoring high and low speed pressures. The air pressure switches have ﬁxed settings and are not adjustable.

2. The furnace is equipped with manual reset rollout switch(es) in the event of burner ﬂame rollout. The switch will open on temperature rise and shut off gas supply through the ignition control module. Flame rollout can be caused by insufﬁcient airﬂow for the burner ﬁring rate (high gas pressure), blockage of the vent system or in the furnace heat exchanger. The furnace should not be placed back in operation until the cause of rollout condition is identiﬁed. The rollout switch can be reset by pressing the button on top of the switch.

3. The furnace is equipped with a ﬁxed temperature high limit switch mounted on the vestibule panel that shuts off gas to the heater through the ignition control module in the event of reduced circulating airﬂow over the heat exchanger. Reduced airﬂow can be caused by motor failure of the circulating air blower, dirt, blockage or restriction of the air inlet or outlet to the unit. The high limit switch will automatically reset when the temperature drops to 30°F [16.7°C] below the setpoint. Determine the cause of the reduced airﬂow and correct.

WARNING

A secure and effective functioning gas burner requires sufﬁcient combustion gas exhaust discharge. Disabling a security device such as a pressure sensitive switch on a gas device is dangerous and can be fatal. This can also prevent proper functioning of the device and will result in the guarantee being void. Do not attempt to disable the pressure switch to place the heater in operation. Contact a qualiﬁed service agency.

4. A circulating blower air proving pressure switch is installed that breaks power to the burner circuit to disable the furnace in the event of loss of circulating airﬂow over the heat exchanger. Loss of airﬂow can be caused by a motor failure, broken fan drive belt or restriction of the air inlet or outlet to the unit. A loss in circulating airﬂow, if not detected early, can cause the furnace to cycle on high limit which can cause overheating and damage to internal components.

WARNING

The circulating blower air proving switch is adjustable and must be set properly to avoid damage due to furnace cycling on high limit.

Maintenance

Furnace Module Inspection

Turn off all electrical power to the unit before inspection and servicing.

1. The furnace should be inspected annually by a qualiﬁed service agency. The condition of the burners, heat exchanger, draft inducer, vent system, operating controls and wiring should be determined. Check for obvious signs of deterioration, accumulation of dirt and debris and any heat or water related damage. Any damaged or deteriorated parts should be replaced before the unit is put back into service.

CAUTION

If any of the original wiring needs to be replaced, it must be replaced with wiring materials suitable for 105°C. Label all wires prior to disconnection when servicing unit. Wiring errors can cause improper or dangerous operation. Verify proper operation after servicing.

2. Clean burners, heat exchanger, draft inducer and vent ducts. Periodically clean the screens in the vent terminal (where applicable).

3. Check heat exchanger for cracks. If any are present, replace heat exchanger before putting unit back into service.

4. Check the attachment point of the furnace module to the cabinet or ducts to verify that they are airtight.

5. Check the automatic gas valve to ensure that the gas valve seat is not leaking.

Furnace Module Operation Check

1. Turn on power to the unit and set thermostat or heat controller to call for heat, allowing furnace module to operate.

2. Check for proper start-up and ignition as outlined in the Start-up section.

3. Check the appearance of the burner ﬂame (see Figure D10 and Figure D11).

4. Return thermostat or heat controller to normal setting.

5. Refer to the appliance manufacturer’s instructions for annual maintenance procedures on the complete unit.

Replacement Parts

Replacement parts for the gas-ﬁred furnace module are available through our Parts and Service Department at:

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 57

Venmar CES Inc. 1502 D Quebec Avenue Saskatoon, SK S7K 1V7 Email: venmarservice@venmarces.com Phone: 1-866-4-VENMAR (1-866-483-6627) Fax: 1-800-667-3716

SN Sequence of Operation – On/off Operation

Fenwal 35-61 Series Direct Ignition Control with Two-stage Gas Valve

When system is powered up 24 VAC will be applied to the ignition control (IC) terminals 24 VAC/R. The control will reset, perform a self check routine, initiate full time ﬂame sensing, ﬂash the diagnostic LED for up to four seconds and enter the thermostat scan standby state.

Call for Heat

1. Thermostat (controller) closes on call for heat powering terminal T2.

2. 24 VAC to is supplied to IC terminal TH, provided limit switch is in closed position.

3. The control will check that pressure switch contacts are open (IC terminal PSW is not powered).

4. Combustion blower is then energized at high speed through IC terminal IND.

5. When the air switch (APS-1) closes, a 15 second prepurge period begins.

6. At end of pre-purge period, the spark commences and the gas valves (both ﬁrst and second stage) are energized for the trial for ignition period.

7. Burners ignite and cross light, operating at maximum input rate (manifold pressure set at 3.3” to 3.5“ w.c.).

8. When ﬂame is detected by ﬂame sensor the spark is shut off immediately and gas valve(s) and combustion blower remain energized.

9. During heating operation, the thermostat, pressure switch and main burner ﬂame are constantly monitored to assure proper system operation.

10. When the thermostat (controller) is satisﬁed and the demand for heat ends, the main valves are de-energized immediately, the control senses loss of ﬂame and a 30 second post-purge occurs before de-energizing the combustion blower.

11. If ﬂame is lost during an operational cycle, the control will respond within 0.8 seconds. The spark will be energized for a trial for ignition period to attempt to relight burners and prove ﬂame sensor. If ﬂame is reestablished, normal operation resumes.

Ignition and Operational Failures During a Call for Heat Result in Lockout of the Ignition Control

1. If the burners fail to light or carryover during a trial for ignition, the control will attempt two additional ignition trials. If no ﬂame is present at the ﬂame sen-

sor within 10 seconds, the spark and gas valve will be de-energized. A 15 second inter-purge period begins and the combustion blower continues to run. After the inter-purge period another ignition trial will take place.

2. If burner fails to light or prove the ﬂame sensor following the two additional trials the control will go into lockout. The valve relay in the IC will be deenergized shutting of the gas valve immediately and the combustion blower following a 30 second postpurge period.

Recovery from Lockout

1. If the thermostat is still calling for heat one hour after a lockout occurs, the control will automatically reset and initiate a call for heat sequence.

2. The ignition control may also be manually reset, by turning the thermostat down and back up to previous temperature setting or removing power (24V) to IC terminal 24VAC.

Fault Conditions and LED Key

LED Steady On Internal control fault 1 Flash Combustion airﬂow fault 2 Flash Flame with no call for heat 3 Flash Ignition lockout

LED ﬂashes on for ¼ second and off for ¼ second during fault condition. Pause between fault codes is three seconds.

1. If during the initial call for heat the air switch contacts are closed for 30 seconds without an output to the combustion blower, an airﬂow fault occurs (one LED ﬂash) and control will remain in this mode.

2. If the airﬂow switch remains open (or a rollout switch is open) for more than 30 seconds after the combustion blower output (IND) is energized, an airﬂow fault occurs (one LED ﬂash) and control will stay in this mode with combustion blower on, waiting for airﬂow switch (or rollout) to close.

3. If the airﬂow signal is lost during operation, the control immediately de-energizes the gas valve and maintains blower operation. If the call for heat remains and proper airﬂow is not detected, airﬂow fault occurs (one LED ﬂash). If proper airﬂow is detected at any time, the normal sequence will begin with prepurge.

4. If the main valve fails to close properly at the end of a heating cycle and a ﬂame is maintained, the combustion blower will continue in operation. If the valve does close completely later removing the ﬂame signal, the blower will run for the post purge period and shut off.

5. Refer to Table D3 for further LED code troubleshooting.

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HF Sequence of Operation – Two-stage Operation with 2 Speed Controller

Fenwal 35-61 Series Direct Ignition Control with TR1 Timer Relay Control

When system is powered up 24 VAC will be applied to the ignition control (IC) terminals 24 VAC/R and to the Timer Relay Control (TR1). The ignition control will reset, perform a self-check routine, initiate full time ﬂame sensing, ﬂash the diagnostic LED for up to four seconds and enter the thermostat scan standby state. The amber light on the TR1 will be lit indicating it is in the ready position.

Call for Heat

1. Thermostat (controller) (ﬁrst stage or ﬁrst and second stage) closes on call for heat.

2. 24 VAC to is supplied to IC terminal TH, provided limit switch is in closed position.

3. The control will check that pressure switch contacts are open (IC terminal PSW is not powered).

4. Combustion blower is then energized at high speed.

5. When the air switch (APS1) closes, a 15 second prepurge period begins.

6. At end of pre-purge period, the spark commences and the ﬁrst and second stage gas valves are energized for the trial for ignition period.

7. Burners ignite and cross light, operating at maximum input rate (manifold pressure 3.5” w.c.).

8. TR1 is powered (Terminal 7) simultaneously (SR LED lit) and begins timing a 90 second warm-up period while maintaining the combustion blower at high speed (FR LED lit). The TR1 will maintain this mode of operation, regardless of status of thermostat second stage.

9. When ﬂame is detected by ﬂame sensor, the spark is shut off immediately and gas valves and combustion blower remain energized.

10. When the initial timer in TR1 times out, it defaults the gas valve to low ﬁre and the combustion blower to low speed and returns control of the operating mode to the temperature controller. The SR LED turns off and the MR LED is lit.

11. If the controller is calling for second stage heat TR1 Terminal 6 is powered. After a short time delay (approximately 15 seconds), the system switches the combustion blower to high speed (FR LED lit) and the second stage gas valve at 3.5” w.c. manifold pressure (CR LED lit), provided the high air pressure switch (APS2) is proved.

12. During heating operation, the thermostat, pressure switch and main burner ﬂame are constantly monitored by the IC to assure proper system operation.

13. Operation continues on high ﬁre until the second stage thermostat is satisﬁed, opening the second stage contact and de-energizes Terminal 6 on the

TR1, turning off the second stage gas valve and returning the combustion blower to low speed.

14. When the thermostat (controller) is satisﬁed and the demand for heat ends, the ﬁrst stage valve is de-energized immediately, the control senses loss of ﬂame and a 30 second post-purge occurs (at high speed) before de-energizing the combustion blower.

Ignition and Operational Failures During a Call for Heat Result in Lockout of the Ignition Control

1. If ﬂame is lost during an operational cycle, the control will respond within 0.8 seconds. The spark will be energized for a trial for ignition period to attempt to relight burners and prove ﬂame sensor. If ﬂame is re-established, normal operation resumes

2. If the burners fail to light or carryover during a trial for ignition, the control will attempt two additional ignition trials. If no ﬂame is present at the ﬂame sensor within 10 seconds, the spark and gas valve will be de-energized. A 15 second inter-purge period begins and the combustion blower continues to run. After the inter-purge period another ignition trial will take place.

3. If burner fails to light or prove the ﬂame sensor following the two additional trials the control will go into lockout. The valve relay in the IC will be deenergized shutting of the gas valve immediately and the combustion blower following a 30 second postpurge period.

Recovery from Lockout

1. If the thermostat (controller) is still calling for heat one hour after a lockout occurs, the control will automatically reset and initiate a call for heat sequence.

2. The ignition control may also be manually reset, by turning the thermostat (controller) down and back up to previous temperature setting or removing power (24V) to IC terminal 24 VAC.

Fault Conditions and LED Key

LED Steady On Internal control fault 1 Flash Combustion airﬂow fault 2 Flash Flame with no call for heat 3 Flash Ignition lockout

LED ﬂashes on for ¼ second, and off for ¼ second during fault condition. Pause between fault codes is three seconds.

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3. If the airﬂow signal is lost during operation, the control immediately de-energizes the gas valve and maintains blower operation. If the call for heat remains and proper airﬂow is not detected, and airﬂow fault occurs (one LED ﬂash). If proper airﬂow is detected at any time, the normal sequence will begin with pre-purge.

5. Refer to Table D3 for further LED code troubleshooting.

MH Sequence of Operation – 20–100% Modulation with 2 Speed Controller

Fenwal 35-61 Series Direct Ignition Control, TR1 Timer Relay Control and SC30 Modulation Control

Call for Heat

1. Thermostat (heat enable) closes on call for heat.

2. 24 VAC to is supplied to IC terminal TH, provided limit switch is in closed position.

3. The control will check that pressure switch contacts are open (IC terminal PSW is not powered).

4. Combustion blower is then energized at high speed.

5. When the air switch (APS1) closes, a 15 second prepurge period begins.

6. At end of pre-purge period, the spark begins and the ﬁrst stage and second stage gas valves are energized for the trial for ignition period.

7. TR1 is powered (Terminal 7) simultaneously (SR LED lit) and begins timing a 90 second warm-up period while maintaining the combustion blower at high speed (FR LED lit) and powers the SC30. The SC30 will output 12 to 13 VDC to the modulating control valve during the timing duration (90 seconds) of TR1, regardless of the analog input signal to SC30 Terminals 7 and 8.

8. Burners ignite at an intermediate high ﬁre condition (manifold pressure 2.5” w.c. or higher; the SC30 control provides 12.5 to 13.0 VDC to modulating valve) and cross light.

9. When ﬂame is detected by ﬂame sensor, the spark is shut off and gas valve(s) and combustion blower remains energized.

10. When the initial timer in TR1 times out, it defaults the gas valve to low ﬁre and the combustion blower to low speed and returns control of the operating mode to the building temperature controller. The SR LED turns off and the MR LED is lit.

11. If the controller is providing an analog signal between 0.5 and 5.3 VDC to the SC30 control, the system will continue to run at low speed combustion blower and with only the ﬁrst stage valve open. The modulating valve will be powered proportional to the input voltage signal from the controller, and will open or close changing the gas manifold pressure. Manifold pressure will vary from 0.3–1.2“ w.c. operating in this mode.

12. If the signal increases above 5.3 VDC, the SC30 relay closes powering Terminal 6 on the TR1 and starts a second time delay of 15 seconds. At the end of this time delay the fan switches to high speed (FR LED lit) and the second stage gas valve opens (CR LED lit) through the TR1 (Terminal 9) provided the high air switch contacts are closed. The manifold pressure will vary from 1.4–3.5” w.c. in this mode.

13. During heating operation, the thermostat, pressure switch and main burner ﬂame are constantly monitored by the IC to assure proper system operation.

14. Operation continues in the high ﬁre mode until the controller input signal to the SC30 control drops to

4.7 VDC. At this point the SC30 relay circuit opens (SC30 terminal 5 has no output) de-energizing the second stage valve and the TR1 switches the combustion blower to low speed operation. Low ﬁre modulation will continue as in Step 11.

15. When the thermostat (temperature controller) is satisﬁed and the demand for heat ends, the heat enable contact opens and the ﬁrst stage valve is de-energized immediately, the control senses loss of ﬂame and a 30 second post-purge occurs (at high speed) before de-energizing the combustion blower.

Ignition and Operational Failures During a Call for Heat Result in Lockout of the Ignition Control

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the inter-purge period another ignition trial will take place.

Recovery from Lockout

1. If the thermostat (controller) is still calling for heat one hour after a lockout occurs, the control will automatically reset and initiate a call for heat sequence.

2. The ignition control may also be manually reset, by turning the thermostat (controller) down and back up to previous temperature setting or removing power (24V) to IC terminal 24 VAC.

IC Fault Conditions and LED Key

LED Steady On Internal control fault 1 Flash Combustion airﬂow fault 2 Flash Flame with no call for heat 3 Flash Ignition lockout

LED ﬂashes on for ¼ second, and off for ¼ second during fault condition. Pause between fault codes is three seconds.

Refer to Table D3 for further LED code troubleshooting.

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Table D3: LED Code Troubleshooting

LED Code System Description Actions

None

Steady on

No power to T1

No operation

Open

2 Flashes

limit switch

1 Flash

2 Flashes

Airﬂow fault

Flame fault

Flashes Lockout

On call for heat, nothing happens.

24 VAC across terminal 24 VAC/V2-Gnd when thermostat calling for heat.

Thermostat call for heat. No power across terminals V1/V2 on control.

Pressure switch contacts in closed position for 30 seconds with no output to combustion blower. Remains in this mode with combustion blower off.

Open pressure switch or ﬂame rollout switch when inducer (IND terminal) is energized. If switch remains open for more than 30 seconds after combustion blower is energized, control will remain in this mode with IND terminal (blower) energized.

Flame sensor failure/ﬂame present with no call for heat.

Failure to light or carryover. Loss of ﬂame or ﬂame signal during ignition or operating cycle. Control will initiate up to three ignition re-trials before lockout.

Check for open fuse or circuit breaker. Check for poor wiring connection. Check for failed 24 volt transformer. System fault. Repeated lockouts (ﬁve) during continuous call for

heat. Check input voltage and inlet gas pressure during operation. Check for condensate or blockage in air tube or pressure switch. Check for blocked vent condition or obstruction in heat ex-

changer tubes. Control fault; replace ignition control. Check for proper operation of circulating air supply system and

for air ﬁlter blockage. Check manifold pressure when limit cools and closes. Natural gas 3.5” w.c./LP gas 10” w.c. Low combustion blower air output. Flue gas temperature exceeds 550°F. Inspect for debris accumulation, proper wheel attachment, proper voltage to blower. Check for short in wiring to pressure switch.

Check pressure switch for closed contacts (with leads disconnected). Replace pressure switch. Failed combustion blower. Check connections and air tube from draft inducer to air switch

for leaks. Check rollout switch manual reset; depress reset. Check supply tube from draft inducer housing to pressure

switches for condensate; drain line and re-connect. Check pressure switch for condensate accumulation. Replace pressure switch. Check for voltage to gas valve with thermostat in ‘Off’ posi-

tion. Valve should not be powered. If valve is not energized, check for gas ﬂow (manifold pressure reading greater than 0). If gas ﬂow is present, turn off main shut-off valve and replace gas valve. Verify gas supply available and operation of gas valve – manifold pressure at start of ignition cycle. Check for power to valve terminals Low and Com while spark is energized. Is spark present? If no, check igniter for debris between electrodes, cracked ceramic and check ignition wire for short to ground. Check ﬂame sensor wiring connections to electrode and control and for any abrasions. Check for cracked ceramic on ﬂame sensor or grounded sensor rod. Verify that ample air supply and proper venting of ﬂue gases occurs during operating cycle. Check for circulating air leaks into burner compartment during operation. Check for re-circulation of ﬂue gases into combustion air supply.

If all conditions satisfactory, replace ignition control.

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IG Series Drum and Tube Gas-ﬁred Duct Furnace Module

WARNING – FOR YOUR SAFETY

The use and storage of gasoline or other ﬂammable vapors and liquids in open containers in the vicinity of this appliance is hazardous.

If you smell gas:

1. Open windows.

2. Do not touch electrical switches.

3. Extinguish any open ﬂame.

4. Immediately call your gas supplier.

WARNING

• Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the Installation, Operating and Maintenance Instructions thoroughly before installing or servicing this equipment.

• Gas-ﬁred appliances are not designed for use in hazardous atmospheres containing ﬂammable vapors or combustible dust, in atmospheres containing chlorinated or halogenated hydrocarbons, or in applications with airborne silicone substances.

Introduction

WARNING

1. Provincial/state regulations require that service mechanics that work on combustion equipment must be licensed.

2. Contact with moving parts can cause injury or property damage. Automatic control devices may start the duct furnace without warning. To prevent accidental start-up, the maintenance personnel should always lockout all power supplies before working on the duct furnace. A duct furnace will often have more than one power connection point; disconnect all sources of power before servicing.

3. Refer to the rating plate for fuel input and supply pressures.

4. Do not attempt to start the burner if the duct furnace is full of vapor or gas, or if the combustion chamber is very hot.

5. Do not use gasoline, crank case oil or any oil containing gasoline for fuel.

6. Do not burn garbage or paper in this duct furnace. Never leave paper or combustible material near the duct furnace.

7. Shut off the manual fuel supply valve if the burner is shut down for an extended period of time.

General

1. These manuals have been prepared to assist in the installation, operation and maintenance of your duct furnace. It is good practice to know as much as possible about your duct furnace before trying to install or operate it. Read the contents carefully before proceeding. Due to the custom nature of this duct furnace, not all possibilities are addressed in this manual. In cases where a special application is not covered, the customer or installer can obtain information from a Venmar CES sales representative or the factory.

Notes

1. Please disregard any information and/or data covering optional components not supplied with the duct furnace.

2. Do not destroy or remove information from this instruction manual. Leave this instruction in the electrical enclosure of the duct furnace.

Warranty

Coverage and Terms

1. Venmar CES standard warranty applies, provided the duct furnace has been connected in accordance with these instructions and operated under normal conditions, Venmar CES will, at its option repair or replace any defective component.

Exclusions

1. Except as herein expressly stated, Venmar CES does not warrant this product in any manner. There are no other expressed or implied warranties, including any warranty of merchantability or ﬁtness for a particular purpose. This warranty does not cover damage, which occurs in transit, or resulting from alteration, accident, misuse or abuse from failure to carry out recommended normal maintenance. Any technician’s travel and labour expenses, which result from claims against this warranty, are the responsibility of the purchaser. In addition, it does not cover any proximate, incidental or consequential damages resulting from the failure of defective components workmanship. Venmar CES’ sole obligation and the purchaser’s exclusive remedy for breach of any warranty shall be, at Venmar CES’ option, to repair or replace any defective component.

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2. Venmar CES warranty is void if:

a. The duct furnace is not installed by a qualiﬁed

heating contractor in accordance with provisions of this service manual and safe practices.

b. The duct furnace was not subject to only normal

use in service and was misused, neglected, altered or otherwise damaged.

c. The duct furnace is allowed to operate during

building construction period.

d. The duct furnace is installed without proper

clearance to combustible materials or located in a conﬁned space without proper ventilation for combustion.

e. The duct furnace is operated in atmospheres

containing ﬂammable vapors, chlorinated or halogenated hydrocarbons.

f. The temperature rise across the duct furnace is in ex-

cess of that shown on the duct furnace rating plate.

g. The duct furnace was operated at any time out-

side its published capacity and/or with any other fuel than prescribed.

h. Field wiring is not in accordance with the wiring

diagram furnished with the heater.

i. Any automatic controls were inoperative during

duct furnace operation.

j. Proper maintenance is not provided on a regular

basis as outlined.

k. The start-up report, which is in the envelope in-

side the control panel, is not returned.

Return Procedures

1. To return defective products under these warranty terms, please contact your supplier or a Venmar CES customer service representative at 1-800-563-6695.

2. Products returned to the factory must ﬁrst be authorized and a return authorization number provided. Return transfer must be prepaid.

Installation Instructions

WARNING

This duct furnace must be installed by a qualiﬁed, licensed ﬁtter in accordance with local building codes and the current edition of CAN\CGA-B149 (1,2) for installation in Canada and applicable provincial regulations for the class; which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made. In the United States the duct furnace should be installed in accordance with Z223.1 for the installation of Gas Burning Appliances and Equipment.

Installation Clearances

1. The duct furnace is designed to be installed within an air handler cabinet within the airstream with the duct furnace burner wall forming part of the airstream wall and with the burner and controls outside of the airstream.

2. Check that the duct furnace is installed in accordance with the allowable clearances from unprotected combustibles as shown on the duct furnace nameplate. The air handler enclosing the duct furnace in the airstream should have insulated walls, ﬂoor and ceiling.

3. For safety and service, the following minimum clearances and guidelines shall be observed:

Table D4: Minimum Clearance Requirements

Clearance Requirement

Top 6” [15.2 cm] 0

Burner side 24” [61 cm] 39” [100 cm]

Flue 18” [45.7 cm] 24” [61 cm] Opposite

burner side Front/back 6” [15.3 cm] 24” [61 cm]

Type of ﬂoor Non-combustible 0

Minimum Clearance from Combustible Construction

6” [15.3 cm] 0

Minimum Clearance for Accessibility

4. The National Electrical Code (NEC or CEC) requires a minimum of 39” [1 m] service space between the face of any electrical enclosure and any wall or obstruction.

5. Provide sufﬁcient clearance to open doors, install piping and ducting, ﬂame observation port, high limit switch, control panel, main fan motor and all access panels/doors.

General Installation

1. Safety considerations to determine if the duct furnace is equipped with all of the safety devices required for the particular application is the responsibility of the air handler manufacturer. Safety considerations include the accessibility of the equipment to nonservice personnel, the provision of electrical lockout switches, maintenance procedures and automatic control sequences.

2. Clearly identify all emergency shut-off devices.

3. The duct furnace must not be operated in the presence of chlorinated vapors. When such vapors mix with the products of combustion, highly corrosive compounds result, which will cause the premature failure of the heat exchanger and other components.

4. Check that there are, or will be, no explosive, ﬂammable or toxic vapors, or abnormal dust in the area where the duct furnace is located or operated.

5. It is important to seal all connections to prevent air leakage and system performance problems. Provide removable access panels on both the upstream and downstream sides of the duct furnace in the air handler or ductwork. These openings shall be accessible when the duct furnace is installed and shall be sized to allow the observation of smoke or reﬂected light inside the casing to indicate the presence of leaks in

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the heat exchanger. The covers for the openings shall

The water level would be 1“ above the top of the “U” of the trap

The water level would be 1” below the bottom of the entrance to the drain.

be attached in such a manner as to prevent leaks.

6. Seal the perimeter of the duct furnace between the outside casing and the inside of the air handler to prevent air bypassing or leakage.

7. When the duct furnace is installed in an enclosed heater room, it is imperative that the heater room itself is not used as an air plenum. Ductwork must be used for all supply and return air to and from the duct furnace air handler, as well as any other fans, which may be installed in the same room.

8. Particular attention should be given to service access to all operating controls.

9. If air handlers are mounted indoors, ensure that any exposed electrical controls and automatic gas ignition control systems are not exposed to water spray, rain or dripping water.

10. If air handlers are mounted outdoors, provide an enclosure to protect the burner and electrical controls from the elements. This enclosure must be sealed from the airstream and provided with air intakes for combustion. Air intakes should be a minimum of 12” [305 mm] from the base of the air handler to prevent blockage by snow and be sized per Combustion Air

Requirements and Exhaust Stacks and Venting. If

the furnace is equipped with an induced draft fan, increase air intakes by 25%. The enclosure access must be sized to allow for easy access and removal of the burner and controls. The enclosure venting must be sized to prevent the ambient temperature from exceeding 125°F [52°C] or the maximum rating for components.

11. Check that the duct furnace is securely mounted, level and braced and will not be subject to swaying or movement, which would put a stress on electrical connections.

Drains and Traps

1. Heat Exchanger Condensate – The duct furnace is supplied with a condensation removal pipe connection(s). Condensate from the heat exchanger and stack is acidic (pH value approximately 3) and may contain chemical compounds requiring special drainage. Both indoor and outdoor units must have the duct furnace condensate drain connections piped to a sanitary sewer.

WARNING

Do not drain into the building or onto the roof.

Failure to connect the condensate drain to a sanitary sewer can result in combustion gases entering the space, uncontrolled water ﬂow into the building or onto the roof resulting in standing water or large amounts of ice buildup, building damage, injury or death.

The drain must be installed in accordance with all plumbing codes. The condensate is to be drained via ½” PVC or steel pipe with an indirect connection to the plumbing wastes.

For positive gas-fired furnaces (no induced draft exhaust) K = Minimum 0.5” [13 mm] H = Overfire pressure on furnace nameplate “w.c. + 1”

Figure D13: Condensate trap – positive gas-ﬁred furnace

For negative gas-fired furnace (with induced draft exhauster) H = Minimum 8.5” [216 mm] J = Half of H or 4.25” [108 mm]

Figure D14: Condensate trap – negative gas-ﬁred furnace

2. Since the condensate is drained by gravity, avoid long runs of drain piping. If a long run of trapping cannot be avoided or the piping has water ﬂow restrictions such as several elbows, add extra height to provide enough hydrostatic head to overcome the frictional losses. Always slope piping down a minimum of 1/8” per foot [10 mm/m] in the direction of the ﬂow.

IMPORTANT

Where a condensate neutralizer is used, an overﬂow shall be provided such that condensate will be directed to the drain in the event the neutralizer becomes plugged. Indoor installations typically require a condensate trap to be installed to prevent combustion gases entering the space, see Figure D13 for sizing, positive pressure. Outdoor installations may require special attention to drains to prevent freezing and clogging of the drain line.

3. The condensate drain line must include a condensate trap to prevent combustion gases entering the sewer on positive ﬁred furnaces or sewer gases entering the furnace on negative ﬁred furnaces. The discharge of

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the trap must be at atmospheric pressure and not tied into a pressurized line or the trap will not function properly.

4. Never attach drain piping to a closed drain or sewer gases may enter.

5. To function properly, a trap must always be primed. The “U” portion of the trap must be full with water. If the trap is not properly primed, air will be sucked through the trap upon start-up and prevent condensate drainage on negative ﬁred furnaces or combustion gases will be pushed into the sewer on positive ﬁred furnaces. Drains that are inactive will dry out and not function properly. An open tee on the leaving side of the trap is recommended for ﬁlling the trap with water and for maintenance.

IMPORTANT

Outdoor installations may require special attention to prevent freezing and clogging of the drain line. Insulate and heat trace the condensate line portion that is outdoors.

Combustion Air Requirements

1. If the duct furnace is installed in furnace rooms, conﬁned areas or low leakage construction buildings, provisions must be made for combustion air. The heater shall be located such that a negative pressure will not be created, which will starve the burner of combustion air.

2. Air for combustion should be drawn and ducted from outdoors where there is a possibility of exposure to substances such as:

• Chlorinated laundry products

• Carbon tetrachloride

• Permanent wave solutions

• Halogen-type refrigerants

• Chlorinated waxes and cleaners

• Cleaning solvents (perchloroethylene)

• Chlorine based pool chemicals

• Printing inks, paint removers, etc.

• Water softening chemicals

• Cements and glues

• De-icing salts or chemicals

• Anti-static fabric softeners

• Masonry acid washing materials

• Hydrochloric acid

3. In some cases, Local Authorities require that combustion air be ducted directly to the burner. Refer to the relevant installation standards in the current CAN1B149 (1,2) in Canada and Z223.1 in USA. On outdoor air handlers air intakes should be a minimum of 12” [305 mm] from the base of the air handler. If the duct furnace is equipped with an induced draft fan, increase air intakes by 25%.

Exhaust Stacks and Venting

1. Installations must be in accordance with the requirements of authorities having jurisdiction or in the absence of local codes, with the relevant installation standards in the current CAN1-B149 (1,2) in Canada and Z223.1 in USA. Local codes may supersede any of the provisions in the above installation standards.

2. Distances from adjacent public walkways, adjacent buildings, openable windows and building openings, shall conform to these codes.

3. Flue outlets must be located so as to prevent blockage by snow.

4. Building materials must be protected from degradation by ﬂue gases.

5. Flue outlets must have a minimum horizontal clearance from electric meters, gas meters, regulators and relief equipment of 6 feet [1.83 m] to CAN1-B149.1 and B149.2 in Canada and 4 feet [1.22 m] to Z223.1 in USA.

6. Flue outlet pressure must not exceed rating on the nameplate for maximum overﬁre pressure on positive ﬁred chambers or maintain the overﬁre draft pressure for the heater on negative ﬁred chambers with induced draft (ID) fans.

7. All horizontal runs should have a minimum rise of ¼” per foot [21 mm/m] of horizontal run in the direction of discharge to prevent the accumulation of condensate.

8. Stacks shall have means provided for the drainage of condensate.

9. Refer to the rating plate for the category of appliance to select the venting. Consult the authorities having jurisdiction and use a gas-tight, water-tight venting system constructed of material resistant to corrosion by condensate.

10. Do not install dampers or other restrictive devices in the ﬂue vent pipe.

11. Stack terminations must be kept to approved distances from fresh air intakes, rooﬂines, etc. Guy wires may be required to brace the stack above rooﬂines.

12. The stack should be installed in such a manner that access to the duct furnace is not obstructed. Do not support the weight of the stack on the ﬂue connection of the duct furnace.

13. Approved methods must be followed when putting the stack through walls, ﬂoors, roofs, etc.

14. The stack shall have a minimum of at least 18” [457 mm] clearance to combustible material.

15. A duct furnace, if installed in a building, full enclosure or in a location requiring that the vent be extended, shall be vented as prescribed by the authority having jurisdiction.

16. The overﬁre draft measured with a manometer at the test port in the burner compartment must be the same as labeled ‘Overﬁre Draft’ or not exceed the ‘Maximum

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Overﬁre Positive’ pressure ratings on the rating plate of the duct furnace.

17. Power Venting Adjustment – The ﬂue draft should be adjusted at the damper of the induced draft (ID) fan when the duct furnace is operating on high ﬁre.

18. Gravity Venting Adjustment – The ﬂue draft should be adjusted at the damper of the burner fan when the duct furnace is operating on high ﬁre.

Gas Connections

1. Gas-ﬁred duct furnace shall be installed in accordance with: a. In Canada the Installation Codes CAN/CGA B149

(1,2) latest edition and applicable provincial regulations for the class of heater being installed. Authorities having jurisdiction should be consulted before installations are made.

b. In the United States the National Fuel Gas Code,

ANSI Z223.1; for airplane hangers in accordance with the Standard for Aircraft Hangers, ANSI/ NFPA 409; for public garages in accordance with the Standard for Parking Structures, ANSI/NFPA 88A or the Standard for Repair Garages, ANSI/ NFPA 88B and applicable local codes for the class of heater being installed. Authorities having jurisdiction should be consulted prior to the commencement of work.

2. An emergency manual shut down valve should be provided upstream of the piping to the duct furnace and labeled for quick identiﬁcation. Color coding of pipe may be required and is recommended. Check the duct furnace rating plate for the fuel type, supply pressure and input rating.

3. Gas supply pressures higher than 14” w.c. [3.5 kPa] require an additional ﬁeld installed high pressure regulator. The high pressure regulator should have an internal or separate relief valve to protect components to their maximum rated pressure limits. The high pressure regulator and relief valve should, if possible, be mounted at least 5 to 10 feet [1.52 to

3.04 m] upstream from the appliance regulator at the duct furnace. Run the gas line to the duct furnace and mount these items so as not to interfere with or hinder access to the duct furnace or any of its components. Install a 1/8” NPT plugged tapping connection immediately upstream of the gas supply connection to the duct furnace for test gauge connection if the duct furnace is not so equipped.

4. The gas line to the duct furnace should be taken off the top of the main gas line. A drip leg with screwed cap should be installed at the bottom of the vertical drop in the gas line to the duct furnace.

5. Vent the main gas appliance regulator and the pilot regulator to atmosphere. Gas pressure switches, high pressure regulator, high pressure relief valve and the

normally open vent valve (if any of these components are supplied) must be vented to atmosphere separately from all other components. Vent lines should terminate outside the building with a turndown elbow and birdscreen. Vent lines must be sloped to a condensate drip leg. Locate the drip leg ahead of the item being vented to prevent any condensate that may form from draining back into the vented item. Bleed and vent lines shall be installed in accordance with CAN/CGA B149 (1,2) latest edition or the National Fuel Gas Code, ANSI Z223.1.

6. See Gas Manifold Piping Drawing included with submittal drawings.

7. Gas piping must not be used to support, hang or steady the duct furnace.

8. The duct furnace and its individual main manual shut-off valve must be disconnected (in closed position) from the gas supply piping system during any pressure testing of the gas supply piping system at test pressures in excess of ½ psig [3.5 kPa].

9. Duct furnaces are certiﬁed for altitudes of 0 to 2,000 feet [0 to 610 m]. When a duct furnace is installed at elevations above 2,000 feet the input rating shall be reduced at the rate of 4%for each additional 1,000 feet [300 m], in accordance with standard CGA 2.17. A separate label must be afﬁxed next to the duct furnace nameplate indicating the adjustments as follows:

This appliance has been adjusted for use at an altitude of: ___________ feet _______________ m

Adjusted maximum gas input: ________Btu/hr ________ kW Adjusted manifold pressure: __________” w.c. ________kPa Date of adjustment:____________________________ Adjusted by: __________________________________

Electrical Connections

1. All electrical connections to the duct furnace and main disconnect switch shall conform to local codes and: a. In Canada the Canadian Electrical Code Part 1,

(CSA C22.1) and all local codes.

b. In the United States the National Electrical Code

ANSI/NFPA 70 and all local codes.

2. The correct power supply requirements are shown on the duct furnace nameplate.

3. An electrical disconnect switch having adequate ampacity (see duct furnace nameplate for voltage and ampacity), if not provided as part of the duct furnace, shall be installed in accordance with Article 430 of the National Electrical Code, ANSI/NFPA 70.

4. The duct furnace must be electrically grounded.

5. Mount and wire all external controls to the duct furnace (i.e. remote control panel, temperature controller, interlocks with external electrical circuits or any other auxiliary electrical item). Numbered terminals are pro-

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vided in the remote control cabinet and on the junc-

tion box on the duct furnace for the connection of these controls (see wiring diagram). Check inside the control panel for labels indicating entry location(s) for ﬁeld installed wiring and control wiring.

6. Dotted lines on a wiring diagram indicate ﬁeld wiring by the Installer.

7. Solid lines on the wiring diagram indicate factory wiring by the Manufacturer.

8. Fuses are furnished and installed in accordance with the applicable Electrical Code. If replacement is necessary the original fuse amperage shall be adhered to. Failure to do so may result in damage to the components within the electrical system.

9. If the duct furnace is to be installed to supply air to an area where freeze-up protection is needed in the event of burner shut down, then a low temperature limit control is recommended.

10. When connecting a power supply to a three-phase motor, take care that the three-phase wiring gives you the correct motor and blower rotation on all motors.

11. Replacement wiring must be equivalent to original wire. See wiring diagram for requirements for shielded or twisted wire.

12. If a space thermostat is used with the duct furnace, locate the thermostat so that cold drafts and hot discharge airstreams do not affect its performance. Do not mount the thermostat on the casing on the duct furnace or any other location where it may be affected by radiated and conducted heat. Refer to the instruction furnished with the thermostat for further details.

Air Distribution and Throughput

1. The duct furnace is designed for constant airﬂow operation. An air proving interlock switch is provided to ensure minimum airﬂow over the combustion chamber prior to burner operation. The range of airﬂow and the pressure drops for each frame size are given in the submittal drawings.

2. The duct furnace must be installed on the positive or pressure side of the air circulating blower.

3. Allow the air circulating blower to run for a sufﬁcient period after the burner is shut down to cool off the heat exchanger, approximately ﬁve minutes.

4. For multi-volume applications the burner input rate must be restricted in proportion to the airﬂow rate so the maximum design temperature rise and minimum airﬂow is not exceeded.

5. The duct furnace must be installed with sufﬁcient upstream and downstream clearance to provide unobstructed and even airﬂow across the openings.

CAUTION

Failure to provide even airﬂow can cause overheating and premature failure.

IMPORTANT

Do not split or branch off leaving ducts or mount temperature sensors directly after the duct furnace allowing sufﬁcient distance for air temperature to blend evenly. Allow approximately two equivalent duct diameters. Equivalent diameter = SQRT (4 AB/PI).

Duct Furnace Start-up and Operation

Precautions Before Starting the Duct Furnace

1. Provincial or state regulations frequently require that service mechanics that work on combustion equipment must be licensed. Unqualiﬁed personnel should not start the duct furnace.

2. Refer to the notes in the Introduction, at the beginning of this manual before continuing.

WARNING

Do not attempt to start the burner if the duct furnace is full

of vapor or gas, or if the combustion chamber is very hot.

Start-up Checklist

IMPORTANT

When starting up the duct furnace for the ﬁrst time or if it has been shut down for an extended period of time the same start-up procedures, as outlined in Start-up Checklist, Start-up Instructions and Restarting After Ignition

Failure should be followed.

1. Set the electrical disconnect in the ‘Off’ position.

2. Set all additional switches in the ‘Off’ position.

3. Close the main manual gas valve, pilot manual gas valve, main and pilot manual ﬁring valves.

4. Check the supply voltage. Voltage must be within 10% of nameplate rating. If not, consult the power company and have the voltage condition corrected before start-up.

5. Check all electrical connections on controls and in the control cabinet. Tighten if necessary.

6. Check all fuse holders. All fuses must be properly installed.

7. Check all motor thermal overload settings against the rating plate ﬁgures. Push the thermal manual reset button on all motor starter overloads.

8. Check that all items shipped loose or unassembled such as control panel, thermostats, etc. have been correctly installed.

9. Check that all external electrical controls and interlocks have been correctly mounted and wired.

10. Check that all power supplies and control wiring has been inspected and approved by the Local Authorities having jurisdiction.

11. Check setpoints of temperature controls. Refer to the wiring diagram on the duct furnace and set to

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the temperature settings indicated. The temperature limiting control setpoints are given below for most duct furnace installations, however refer to the wiring diagram.

High Limit

200°F [93°C]

Fan Switch

125°F [52°C] On 90°F [32°C] Off A duct furnace should never be allowed to cycle over a prolonged period on the high limit. The high limit is not an operating but a safety control to prevent excessive temperatures. If cycling on the high limit is noted, corrective measures should be taken immediately. Failure to do so could cause damage to the duct furnace.

12. Check burner and induced fan wheels set screws. Tighten if necessary.

13. Check that the exhauster (induced draft fan) or vent discharge is free of obstructions.

14. Check that the air inlet to and the air discharge from the duct furnace are free of obstructions.

15. Check that the gas piping has been installed in accordance with CAN1 B149 (1,2) or NFPA 54, and has been tested for leaks and approved.

16. Check with the local gas utility that the gas supply is open from the street gas main to the building metering station and the metering station has been completed, tested and turned on.

17. Ensure that the type of gas (natural or propane) supplied and the gas pressure to the duct furnace corresponds with the type and gas inlet pressure indicated on the nameplate of the duct furnace.

18. Check the gas piping to ensure that the proper drip legs, regulators, relief valves and vent lines are installed.

19. On systems where a high pressure regulator and relief valve are installed, check that the spring in the high pressure regulator has been screwed down to approximately the middle of its adjustment range.

20. Purge the gas line from the meter to the duct furnace.

Start-up Instructions

1. Before proceeding, complete the Start-up Checklist.

2. Read the Sequence of Operation, while at the same time, tracing the sequence through the electrical wiring diagram.

3. Set the duct furnace disconnect switch ‘On’ (fan and burner control switches are still ‘Off’ and burner thermostat is set for no heat with main and ﬁring valves still closed).

4. Set fan control switch ‘On’. Run the fans without heat to check fan operation ﬁrst.

5. The duct furnace is provided with an air proving interlock switch to ensure minimum airﬂow over the combustion chamber prior to burner operation. Set

the switch to open just below the design airﬂow. Adjust the air throughput to be within the range speciﬁed on the duct furnace rating plate.

6. Set the burner operating switch, controls, remote panel switches, etc. to ‘On’ or to the ‘Winter’ position (the main and ﬁring valves are still closed) to check operation of the induced draft (ID) fan (if so equipped) and burner combustion air blower. The high ambient thermostat, if provided, is located to sense the inlet or outdoor air temperature and set to shut down the burner if the inlet air rises above setpoint. If discharge or room thermostats are used these should be set to provide heat. If the duct furnace is started up in warm weather it will be necessary to temporarily increase the setting of these controls until the burner control circuit is energized to check operation. Use a signal generator if necessary to vary the signal to the modulating actuator. The induced draft fan if so equipped and combustion air fan should start immediately.

7. Check burner and induced draft fan (if provided) motors for correct rotation. To reverse rotation, ﬁrst set the main electrical disconnect switch to the ‘Off’ position and then interchange any two of the three wires feeding L1, L2 or L3 at the starter.

8. Check the amperage draw of each motor on each phase. Refer to rating plate for Full Load Amps (FLA).

9. Check voltage at duct furnace disconnect switch. If the power is not within 10% of rated, shut the duct furnace down and consult the power company. Voltage should be within 2% on all phase-to-phase readings when compared to each other. A 2% voltage difference could cause as much as a 20% current imbalance.

10. On duct furnaces equipped with modulating controls the modulating gas valve is linked with the combustion air blower air damper. On a start sequence the actuator should be fully open for a portion of the purge interval, then modulate to the low ﬁre or light off position before an ignition attempt is made. This is to ensure four air changes in the combustion chamber. Check the operation of the pre-purge timers, actuator and linkages. Timers and linkages are preset at the factory. Check that the linkage retaining screws are tight.

11. Ensure that the ﬂue is in place and providing overﬁre draft or positive pressure.

12. After the pre-purge, the ignition transformer and pilot solenoid will be energized. Observe the ignition spark for proper location and ﬁrmness. After the trial for ignition time, the ignition transformer and pilot solenoid valve are de-energized and the burner control will lock out. Reset the burner control.

13. Open the main and pilot gas valve (main and pilot ﬁring valves must still be closed) and purge the main

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gas line and pilot line on the duct furnace so that gas is supplied up to the automatic gas valve(s). Do not purge or bleed into the combustion chamber. Check for leaks on duct furnace piping to the automatic shut-off valves and correct.

14. On systems where high pressure regulator and relief valves are installed, check the gas pressure downstream of the high pressure regulator and upstream of the appliance regulator. It must not exceed 14” w.c. [3.48 kPa] or the value on the duct furnace rating plate. Adjust the regulator as necessary.

15. Check the operation of the main automatic gas shutoff valve(s) for through-the-valve or internal seat leakage as outlined in the valve installation and maintenance instructions provided separately.

16. If the duct furnace has high or low pressure gas switches, press the manual reset buttons.

17. Open the pilot manual ﬁring valve (main ﬁring valve must still be closed).

18. Reset the burner control.

19. The pilot should light; if not, re-check the electrical safety circuit. Three or four trials may be needed to purge any air from the pilot line.

20. Refer to the speciﬁc burner control in the Burner Control

Module Troubleshooting Guide for test jack locations

and ﬂame signal reading. The Honeywell RM7897A burner control has an expected DC voltage of between 1.25 and 5 VDC using a 20 kohm per volt meter. The Honeywell S89F burner control should have a ﬂame sensor current reading of at least 0.8 µA and steady. If the ﬂame signal reading is less, then re-adjust the pilot ﬂame or realign the ﬂame detector. If the burner control is equipped with the optional display module the signal can be displayed. Reset the burner control and repeat the ignition cycle several times to ensure a fast igniting and stable pilot ﬂame. Contact Venmar CES Customer Service at 1-866-4-VENMAR (1-866-483-6627) or email tech support at venmarservice@venmarces.com for a copy of the burner control technical manual for further information if required.

21. Open the main manual ﬁring valve. Once the main automatic valve(s) are energized and after the low ﬁre timing relay has elapsed, the control valve actuator will modulate to the setpoint temperature.

22. Check for leaks on duct furnace piping after the automatic shut-off valves and correct.

23. Check combustion air and ﬁring rate settings. The unit has been test ﬁred in the factory for ﬁring rate and combustion. Combustion air and gas linkages have been preset for proper combustion and high and low ﬁre positions have been factory preset. Field conditions, vibration, loose, damaged or replacement parts may require adjustments to be made. These checks should be done by a qualiﬁed service technician.

a. Remove the signal wire to the burner modulating

actuator (Terminals G+ and G−, refer to the electrical diagram for accurate information) and install a 0–10 volt signal generator if this has not been done per Item 6 in the Start-up Instructions. Dial the signal generator to 10 volts. Check the burner manifold pressure at the test point nearest the burner, downstream of the gas control valve against the nameplate for the correct pressure and adjust the appliance regulator if necessary.

b. Check the temperature rise across the heat ex-

changer against the nameplate. The downstream measurement should be done sufﬁciently far downstream where the air temperature readings are even. If the temperature rise is off from the nameplate, then the airﬂow should be corrected. Note mass ﬂow is affected by temperature and temperature rise should be corrected accordingly. The duct furnace should not be allowed to operate above a maximum temperature rise of 115°F [64°C]. Temperature rise is based on 70°F [21.1°C] or standard air conditions. This is a constant volume fan, therefore if the air temperature to the supply fan is less than 70°F [21.1°C] the air will be denser and the mass ﬂow rate will increase which will result in a smaller temperature rise according to the perfect gas law formula: TRa = TRd * (460 + 70)/(460 + Ti)

Where: TRa = temperature rise actual (°F) TRd = Temperature rise design (°F) Ti = Inlet temperature at the supply fan (°F) 460 = Absolute temperature (°F)

IMPORTANT

This is an approximation as the airﬂow increase will cause an increase in static pressure and hence reduce the mass ﬂow slightly and the motor and fan input will also provide a slight increase in temperature rise.

c. Check the overﬁre draft or positive pressure at maxi-

mum input against the nameplate. Make certain that it does not exceed the maximum shown on the nameplate. For power venting the overﬁre draft should be adjusted at the damper of the induced draft (ID) fan when the duct furnace is operating on high ﬁre.

d. Check the CO (Carbon Monoxide) and O2 (Oxygen)

reading at maximum input. O2 readings typically range from 3%–16%. Calculate the AFCO (Air Free CO) reading using the formula: AFCO = (20.9 *COppm)/(20.9–O2%). Adjust the air/gas ratios with the control linkages to keep the AFCO reading below 400. Refer to Burner Linkage and

Low Fire Adjustment for the adjustment proce-

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dure based on the type of linkage supplied with

the duct furnace.

e. Set the signal generator to a midpoint then mini-

mum temperature rise. Repeat Step D above.

f. If the AFCO is over the acceptable limit or if there

is any burner performance problem, refer to

Burner Linkage and Low Fire Adjustment.

24. When the duct furnace installation is complete, start and stop the burner several times to ensure proper operation. Check the amperage draw of each motor.

25. Check operation of the burner control by simulating a ﬂame failure making certain the burner control locks out within the proper time. Contact Venmar CES Customer Service at 1-866-4-VENMAR (1-866483-6627) or email tech support at venmarservice@ venmarces.com for a copy of the burner control technical manual for further information if required.

26. Ensure all safety controls are operative (i.e. burner control, high limit, air proving switches, etc.).

27. Reset all operating controls back to proper setpoints for normal running conditions.

28. Initial start-up has a tendency to relieve the tightness of nuts, bolts and setscrews. Re-check for tightness of hold down bolts, all set screws and keys, and tighten if necessary after approximately eight hours of continuous operation.

Restarting After Ignition Failure

WARNING

Do not attempt to start the burner if the duct furnace is full

of vapor or gas, or if the combustion chamber is very hot.

1. Consult the burner control technical manual for troubleshooting information. If the duct furnace is equipped with the electronic burner control check the status lights on the face of the control. The optional keyboard display module can also provide a wealth of control information and fault history.

2. Set burner control switches to the ‘Off’ position.

3. Set the electrical disconnect to the ‘Off’ position.

4. Check for fuel supply.

5. Check the components in the electrical circuit to the burner control. Check that all screws and connections are tight on the burner control.

6. Close the main manual ﬁring valve.

7. Check the ﬂame detector and ﬂame ignitor. The ﬂame detector and ignitor are located on the combustion head assembly inside the burner and are accessible through the housing cover as shown in the ﬁgures below.

8. Check the condition of the electrical connections and the condition and positioning of the ﬂame rod and spark ignitor. On C4 burners the ﬂame rod protrudes in the center of the retention plate hole and the por-

celain should be ﬂush with the retention plate as in Figure D15 and Figure D16. The ﬂame rod protrudes in the center of the retention plate hole and extends 3-5/8” [92 mm] past on size C6 to C10 burners as in Figure D17 and Figure D18.

9. The spark ignitor is bent at 900 at the tip. On C4 burners the ignitor tip is within 1/16” to 1/8” [1.6 to

3.2 mm] of the pilot gas deﬂector plate as in Figure D15 and Figure D16. On C6 to C10 burners the perpendicular tip portion should be ﬂush with the retention plate and within 1/16” to 1/8” [1.6 to 3.2 mm] of the retention plate as in Figure D17 and Figure D18.

10. Follow the procedures for start-up. Should there be a demand for heat, the duct furnace should attempt to start.

11. Observe the operation very carefully to determine at what point the trouble occurs if it still exists. Consult the burner control technical manual for further troubleshooting procedures.

12. Burner parts for C4 burner outlined in Figure D15: 1 Combustion head 9 Burner housing 10 Air damper 11 Damper shaft 12 Back plate 14 Air inlet cone and screen 15 Motor mounting plate 16 Retention plate 20 Electric motor 21 Ignition transformer 22 Airﬂow switch 26 Linkage arm 27 Control quadrant 28 Site glass retainer 29 Site glass 30 Site glass gasket 31 Ignition electrode 32 Flame rod 33 Junction box 45 Blower wheel

Figure D15: C4 burner description

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P/N 033

P/N 042

P/N 036 P/N 029

0.500 NY

FW 375-125

T68-7C

P/N 035 for 5½” nose P/N 035-1 for 8” nose

P/N 040-1 for 5½” nose P/N 040-2 for 8” nose

P/N 022-1

Flame rod holder

P/N 043

Figure D16: C4 burner combustion head assembly

P/N 04

Shut Down Instructions

General

1. Set the burner operating switch, controls, remote panel switches, etc. to ‘Off’ or to the ‘Summer’ position.

2. To prevent possible gas leaks close the main manual gas valve.

3. If the duct furnace was ﬁring at the time of shut down allow the supply fan blower to run for a sufﬁcient period to cool off the heat exchanger, approximately ﬁve minutes.

4. Set the duct furnace disconnect switch to ‘Off’.

Emergency Shut Down Only

1. Set the duct furnace disconnect switch to ‘Off’.

2. Close the main manual gas valve.

Summer Shut Down

1. If the duct furnace is not required during periods when summertime temperatures drop, then set the burner operating switches, controls, remote panel switches, etc. to ‘Off’. Set the duct furnace disconnect switch to ‘Off’ and close the main manual gas valve.

2. If the duct furnace is to be used for short periods of heating, then set the operating switches, controls, remote panel switches, etc. to the desired position(s).

Maintenance

Figure D17: C6–C10 burner description

3-5/8”

Figure D18: C6–C10 burner combustion head

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

1/16”–1/8”

WARNING

Provincial or state regulations frequently require that service mechanics that work on electrical equipment must be licensed. Although many maintenance items do not require the service of a licensed mechanic, it is recommended that a licensed mechanic supervise any work done on the duct furnace by unlicensed personnel. Unqualiﬁed personnel should not be allowed to work unsupervised.

¼”

Recommended Maintenance

IMPORTANT

The following recommended maintenance schedule should be followed every four months unless otherwise speciﬁed below. It is highly recommended to schedule the maintenance of the duct furnace in the spring and fall as demands are commonly most critical after these periods and serve as good prevention practice. Where the duct furnace is operating under unusual amounts of dust or if other impurities are contained in the air, more frequent inspections are recommended.

1. Inspect the area and make certain that no combustible or hazardous material has been stored within the clearances as shown on the nameplate.

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2. Inspect the stack to make certain there are no obstructions. Check for carbon deposits, soot, scale or rust.

3. Inspect the condensate and drain connections and disposal systems. Check for blockage and trap operation. Clean as applicable.

4. Ensure that there are no obstructions blocking the air supply to the duct furnace or the air discharge from the duct furnace.

5. Check for any vibration or unusual noise. If any are observed, locate the cause and correct.

6. Electrical – Check all wiring for loose connections. Check voltage at the unit (while in operation). Check amperage draw against nameplate ratings. All contactors should be inspected to ensure that contacts are clean and are making good contact. If contacts are pitted or burned badly, replace contactor points. Single phasing and motor burn out may result from bad contacts. Check all fuses and replace blown fuses with equivalent size and type.

7. Controls – Clean and recalibrate all controls and check for proper operation. Repair or replace any controls found faulty.

8. Gas Piping – Check all ﬁttings, valves and lines for leaks. Ensure all vents to atmosphere are clean and free from obstruction. Inspect and clean all drip legs in the fuel line. Inspect all regulators, relief valves, vent valves, manual shut-off valves and gas pressure switches. Check their operation and clean or replace as necessary. Check the operation of the main automatic gas shut-off valve(s) for through-the-valve or internal seal leakage as outlined in the valve installation and maintenance instructions provided separately. Check the fuel supply pressure to the duct furnace.

9. Motors – Inspect motors every three months or 500 hours of operation, whichever is less. Keep the motor clean and the ventilation openings clear. Make certain the mechanical installation is secure and all bolts and nuts are tightened. Check all electrical connectors to be certain that they are tight. Use a Megger periodically to ensure that the integrity of the winding insulation has been maintained. Record the readings and investigate any signiﬁcant drop in insulation resistance.

10. Motor Lubrication – Some motors are complete with permanently lubricated and sealed bearings, which do not require lubrication. Motors with grease nipples and drain plugs have been ﬁlled by the Manufacturer and should always be checked before startup and at regular intervals. a. A recommended lubrication schedule for motors

is given in Table D3 for normal operation. Where conditions are more severe or abnormal the re-lubrication interval should be reduced. Refer to the motor Manufacturer’s instructions. Motors that

run in hot, severe dirt or wet conditions should be lubricated at least every six months.

Table D5: Re-lubrication Schedule

Hours of

Service

(hours/day)

Less than 12 5 years 3 years 1.5 years

More than 12 2 years 1 year 9 months

Up to 7.5 HP 10–40 HP Over 40 HP

Re-lubrication Interval

b. Be sure the grease that is being added to the

motor is compatible with the grease already in the motor. Consult the motor Manufacturer if grease other than Mobil or Polyrex EM is to be used.

c. Clean the grease nipple. Remove the outlet plug.

With motor stopped, add grease slowly until new grease appears at the shaft hole in the end plate or purge outlet plug. Re-install outlet plug.

11. Burner – Inspect the burner and combustion air blower, clean if necessary. See Figure D15 to Figure D18. To clean the combustion air blower, disconnect the wiring on the burner motor, remove the blower/ motor assembly and vacuum the blades or blast with compressed air to remove any dirt buildup. Inspect the ﬂame sensor and ignition electrode and check for cracks, positioning and gap. Test the ignition spark and ﬂame signal. Check that the modulating actuator linkages are tight and operate freely. Perform the ﬁnal combustion check per Start-up Instructions, Item 24.

Recommended Spare Parts – General

1. Spare parts should be ordered at the time the installation if accepted by the Owner. Spare parts will reduce the down time in the event of a failure.

2. The list of spare parts outlined below is considered minimum. Installations in remote locations or where duct furnace operation is essential may require more spare parts than listed. Please contact our service department for recommendations.

3. Minimal spare parts list:

• Two sets of fuses

• One burner control relay module, ﬂame signal

ampliﬁer and purge card

• One ﬂame sensor

• One spark igniter

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Burner Linkage and Low Fire Adjustment

WARNING

Do not attempt to start the burner if the duct furnace is

full of vapor or gas, or the combustion chamber is very hot.

General

1. The procedure in this section needs to be performed only if the performance of the burner is not satisfactory. Refer to Start-up Instructions for directions on how to determine if this procedure is needed.

2. Refer to the notes in the Introduction, at the beginning, and the Duct Furnace Start-up and Operation sections before continuing.

3. Determine the type of linkage employed on the duct furnace and proceed to the corresponding section below.

Cam Linkage

1. A cam linkage is used on positive ﬁred combustion chambers up to and including 1,400 mbh with natural gas and for 7” w.c. inlet pressures only to provide optimum air and gas ratios for combustion throughout its ﬁring range and provides maximum turndown of the burner. The combustion air damper control arm is ﬁtted with a roller bearing and follows a characterized cam as shown in Figure D19. The gas butterﬂy valve is ﬁtted with adjustable control arms and ﬁxed linkages to the actuator.

Figure D19: Cam linkage

2. For your safety and to avoid damaging the equipment, start the linkage and low ﬁre adjustment procedure without gas or power to the duct furnace.

3. Make certain all the joints on the control arms and linkages are tight to begin with. Loose joints could make the adjustment slip and create an unsafe condition.

4. Remove the signal wire to the burner modulating actuator (Terminals G+ and G−, refer to the electrical diagram for accurate information) and install a 0–10 volt

signal generator if this has not been done per Item 6, Start-up Instructions. Dial the signal generator to 2 volts or less. With power off the actuator and linkage should position the combustion air damper to an opened position for maximum air throughput.

5. Close the manual ﬁring valve (M4, refer to the piping diagram), power up the unit and open the main manual gas shut-off valve (M1) to the unit.

6. Start the burner and wait for the purge to complete. During the purge, the combustion air damper should move from maximum purge position (opened position for maximum air throughput) to low ﬁre (closed position for light off). At the same time, the gas butterﬂy valve should rotate from high ﬁre (open position for maximum gas throughput) to low ﬁre (closed position for light off).

7. After the purge, the pilot will ignite. Once the pilot is lit, slowly open the manual ﬁring valve (M4); at the same time look into the burner view port and watch for any ﬂame rolling back around the burner proﬁle plate. If this happens, the amount of gas should be reduced at the butterﬂy valve before continuing. Loosen the swivel joint on the connecting rod at the butterﬂy crank arm and slide the rod to close the valve very slightly. Flame rolling back into the burner could damage some internal burner components. A yellow ﬂame is normal on low ﬁre.

8. Once you have successfully established low ﬁre, start to modulate the burner slowly to high ﬁre, taking a close look at the ﬂame to make sure it runs smoothly and does not roll back into the burner. Once the full modulation (10 volts to the actuator) is reached, verify the gas supply pressure to the unit to make sure it is at least equal to the minimum rated pressure on the nameplate. Please note that the cam follower is not necessarily going to reach the high ﬁre end of the cam proﬁle as the cam can be adjusted for a partial input.

Verify the manifold and overﬁre pressures (chamber

pressure). The differential between the manifold and the overﬁre should be the same as what can be calculated from the values indicated on the nameplate. If it is not correct, increase or decrease the manifold by adjusting the appliance pressure regulator (M3 or SV1). Verify the temperature rise as per the instructions under Start-up Instructions, Item 23b.

Return to the low ﬁre position (less than 2 volts mod-

ulation signal). Verify the position of the air damper in the burner. The cam follower, mounted on the gas butterﬂy valve, should be at one end of cam proﬁle. See Figure D20.

9. Adjust the gas butterﬂy valve opening to obtain a clean combustion on the low ﬁre position. Make sure the Air Free CO (AFCO) is maintained below 400 ppm.

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Figure D20: Low ﬁre typical cam positioning

10. Verify the combustion to make sure it is clean in the intermediate range and on high ﬁre.

11. When the duct furnace adjustment procedure is complete, start and stop the burner several times to insure proper operation.

Fixed Linkage

1. A ﬁxed linkage is used where cam linkage conditions are not met to provide proper air and gas ratios for combustion throughout its ﬁring range and provides limited turndown of the burner. Both the combustion air damper and the gas butterﬂy valve are ﬁtted with adjustable control arms and ﬁxed linkages to the actuator.

2. For your safety and to avoid damaging the equipment, start the linkage and low ﬁre adjustment procedure without gas or power to the duct furnace.

3. Make certain all the joints on the control arms and linkages are tight to begin with. Loose joints could make the adjustment slip and create an unsafe condition.

4. Remove the signal wire to the burner modulating actuator (Terminals G+ and G−, refer to the electrical diagram for accurate information) and install a 0–10 volt signal generator if this has not been done per Start-

up Instructions, Item 6. Dial the signal generator to 2

volts or less. With power off, the actuator and linkage should position the combustion air damper to an opened position for maximum air throughput.

5. Close the manual ﬁring valve (M4, refer to the piping diagram), power up the unit and open the main manual gas shut-off valve (M1) to the unit.

6. Start the burner and wait for the purge to complete. During the purge, the combustion air linkage should move from maximum purge position (opened position for maximum air throughput) to low ﬁre (closed position for light off).

7. After the purge, the pilot will ignite. Once the pilot is lit, slowly open the manual ﬁring valve (M4). Look into the burner view port at the same time and watch for any ﬂame rolling back around the burner proﬁle plate. If this happens, the amount of gas should be reduced at the butterﬂy valve before continuing.

Loosen the swivel joint on the connecting rod at the butterﬂy crank arm and slide the rod to close the valve very slightly. Flame rolling back into the burner could damage some internal burner components. A yellow ﬂame is normal on low ﬁre.

8. Once you have successfully established low ﬁre, start to modulate the burner slowly to high ﬁre, taking a close look at the ﬂame to make sure it runs smoothly and does not roll back into the burner. Verify that the notch on the end of the shaft of the gas butterﬂy valve (M5) does not go past the maximum opening (notch parallel to the gas line). If it does, reduce the span on the burner actuator. Once the full modulation (10 volts to the actuator) is reached, verify the gas supply pressure to the unit to make sure it is at least equal to the minimum rated pressure on the nameplate.

9. Verify the manifold and overﬁre pressures (chamber pressure). The differential between the manifold and the overﬁre should be the same as what can be calculated from the values indicated on the nameplate. If it is not correct, increase or decrease the manifold by adjusting the appliance pressure regulator (M3 or SV1). The burner air damper opening should also be adjusted to get a clean combustion. When it is done, indicate the high ﬁre air damper position on the slotted quadrant attached to the burner air damper rod. Verify the temperature rise as per the instructions under Start-up Instructions, Item 23b.

10. Return to the low ﬁre position (less than 2 volts modulation signal). Verify the position of the air damper in the burner. It should be at the mark indicated on the slotted quadrant from factory adjustments.

11. Adjust the butterﬂy valve opening to obtain a clean combustion on low ﬁre position. Make sure the Air Free CO (AFCO) is maintained below 400 ppm. If you cannot obtain a clean combustion on low ﬁre, you might have to change the burner air damper opening. Put a reference mark of the low ﬁre air damper position on the slotted quadrant.

12. Shut the burner and the entire unit off and turn the power to the unit off. If you do not turn the power off, the burner actuator will continue to modulate and will make the adjustments harder to perform.

13. Use the manual override push button on the burner modulating actuator and make sure the linkage is on the low ﬁre position. Verify that the mark on the quadrant still matches. Rotate the linkage to the high ﬁre position (the notch on the butterﬂy valve should be parallel to the gas train). Verify the position reached on the air damper quadrant versus the mark on the quadrant.

14. If the position was not as expected on high ﬁre, some adjustment will have to be made. Follow these steps: a. Make sure the linkage is on the low ﬁre position.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 75

b. Tighten the burner air damper quadrant at the

screw in the slot so the linkage cannot move.

c. Loosen the rod at one of the two ball joints on

the air linkage.

d. You will now have to perform the adjustment it-

self. Choose the proper adjustment, depending if the damper was not opening enough or too much:

Damper does not open enough

Move the ball joint installed on the driver shaft further from the shaft. Move the ball joint installed on the driven shaft closer to the shaft.

Damper opening too much

Move the ball joint installed on the driver shaft closer to the shaft. Move the ball joint installed on the driven shaft further from the shaft.

e. Tighten the rod at the ball joint and loosen the air

damper.

f. Use the manual override push button on the

actuator to verify if the linkage is now correct. If not, go through the steps above until you get a satisfactory setup.

15. Bring back the power to the unit and turn it on. Verify the combustion to make sure it is clean on low, mid and high ﬁre. Fine tune as necessary.

16. When the duct furnace adjustment procedure is complete, start and stop the burner several times to insure proper operation.

Run/test switch

Sequence status LEDs

Reset push button

Flame simulator input

Flame current test jacks

Captive mounting screw

Plugin purge card

Dust cover

Relay module

Flame amplifier

Figure D21: Flame signal measurement location

Burner Control Module Troubleshooting Guide

RM7897A Burner Control Module

Troubleshooting

The power LED provides fault identiﬁcation when the relay module locks out on an alarm. Fault identiﬁcation is a series of fast and slow-blinking LED lights. The fast blinks identify the tens portion of the fault code (three fast blinks is 30), while the slow blinks identify the units portion of the fault code (two slow blinks is two). Three fast blinks followed by two slow blinks would be fault code 32. This identiﬁes a running interlock on during standby (see Table D4 for Blinking Fault Code List.)

The LED code repeats as long as the fault exists. To clear the fault, press the Reset button.

IMPORTANT

Blink codes do not match fault codes viewed by an S7800 KDM.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 76

Table D6: Blinking Fault Codes and Recommended Troubleshooting

Fault Code System Failure Recommended Troubleshooting

Code 1-1: Low AC line voltage

Code 1-2: AC quality problem

Code 2-1: Unexpected ﬂame signal

Code 2-2: Flame signal absent

Code 2-3: Flame signal over range

Code 3-1: Running/interlock switch problem

Low AC line detected.

Excessive noise or device running on slow, fast or AC line dropout detected.

Flame sensed when no ﬂame is expected during standby or purge.

No ﬂame time present at the end of the pilot ﬂame establishing period; lost during the main ﬂame establishing period or during run.

Flame signal value is too high to be valid.

Running or lockout interlock fault during prepurge.

1. Check the relay module and display module connections.

2. Reset and sequence the relay module.

3. Check the 7,800 power supply and make sure that frequency and voltage meet speciﬁcations.

4. Check the backup power supply, as appropriate.

1. Check that ﬂame is not present in the combustion chamber, correct any errors.

2. Make sure that the ﬂame ampliﬁer and ﬂame detector are compatible.

3. Check the wiring and correct any errors.

4. Remove the ﬂame ampliﬁer and inspect its connections. Reset the ampliﬁer.

5. Reset and sequence the relay module.

6. If the code reappears, replace the ﬂame ampliﬁer and/or the ﬂame detector.

7. If the fault persists, replace the relay module.

1. Measure the ﬂame signal. If one exists, verify that it meets speciﬁcations.

2. Make sure that the ﬂame ampliﬁer and ﬂame detector are compatible.

3. Inspect the main fuel valve(s) and valve connection(s).

4. Verify that the fuel pressure is sufﬁcient to supply fuel to the combustion chamber. Inspect the connections to the fuel pressure switches. Make sure they are functioning properly.

5. Inspect the airﬂow switch and make sure that it is functioning properly.

6. Check the ﬂame detector sighting position; reset and recycle. Measure the ﬂame signal strength. Verify that it meets speciﬁcations. If not, refer to the ﬂame detector and/or ﬂame ampliﬁer checkout procedures in the installation instructions.

7. Replace the ﬂame ampliﬁer and/or the ﬂame detector, if necessary.

8. If the fault persists, replace the relay module.

1. Make sure the ﬂame detector and ﬂame ampliﬁer are compatible.

2. Remove the ﬂame ampliﬁer and inspect its connections. Reset the ﬂame ampliﬁer.

3. Reset and sequence the relay module.

4. Check the ﬂame detector sighting position; reset and recycle. Measure ﬂame strength. Verify that it meets speciﬁcations. If not, refer to the ﬂame detector and/or ﬂame ampliﬁer checkout procedures in the installation instructions.

5. If the code reappears, replace the ﬂame ampliﬁer and/or the ﬂame detector.

6. If the fault persists, replace the relay module.

1. Check wiring; correct any errors.

2. Inspect the fan; make sure there is no air intake blockage and that it is supplying air.

3. Make sure the lockout interlock switches are functioning properly and the contacts are free from contaminants.

4. Reset and sequence the relay module to pre-purge (place the test/ run switch in the ‘Test’ position, if available). Measure the voltage between Terminal 7 and G (Ground); 120 VAC should be present. Switch test/run back to ‘Run’.

5. If Steps 1 through 4 are correct and the fault persists, replace the relay module.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 77

Table D6: Blinking Fault Codes and Recommended Troubleshooting

Fault Code System Failure Recommended Troubleshooting

1. Check wiring to make sure that the lockout interlocks are connected properly between Terminals 6 and 7. Correct any errors.

2. Reset and sequence the relay module.

3. If the fault persists, measure the voltage between Terminal 6 and G (Ground), then between Terminal 7 and G. If there is 120 VAC

Code 3-2: Running/interlock on during standby

Code 3-3: VPS in improper state

Code 4-1: Purge card problem

Code 4-2: Wiring problem/internal fault

Code 4-3: Flame ampliﬁer problem

Code 4-4: Conﬁguration jumper problem

Lockout interlock powered at improper point in sequence or on in standby.

VPS (valve proving switch) in wrong state during VPS test.

No purge card or the purge card timing has changed from the original conﬁguration.

Pilot (ignition) valve terminal, main valve, ignition or main valve 2 was on when it should be off.

Flame not sensed or sensed when it should be on or off.

The conﬁguration jumpers differ from the sample taken at start-up.

at Terminal 6 when the controller is off, the controller switch may be bad or is jumpered.

4. If Steps 1 through 3 are correct and there is 120 VAC at Terminal 7 when the controller is closed and the fault persists, check for a welded or jumpered running interlock or airﬂow switch. Correct any errors.

5. If Steps 1 through 4 are correct and the fault persists, replace the relay module.

1. Check wiring, making sure upstream valve is connected to Terminal 9 and downstream valve is connected to Terminal 17.

2. Conduct valve seat leakage test using a manometer.

3. Reset and sequence the relay module; if fault repeats, test VPS (connected to Terminal 16) is functioning properly; replace if necessary.

4. Reset and sequence the relay module.

5. If fault persists, replace the relay module.

1. Make sure the purge card is seated properly.

2. Inspect the purge card and the connector on the relay module for any damage or contaminants.

3. Reset and sequence the relay module.

4. If the fault code reappears, replace the purge card.

5. Reset and sequence the relay module.

6. If the fault code persists, replace the relay module.

Electrical shock hazard/ﬁre or explosion hazard – Can cause severe injury, death or property damage. Remove system power and turn off power supply.

1. Remove system power and turn off fuel supply.

2. Check wiring; correct any errors.

3. Inspect pilot fuel valve(s) (both places) and connections.

4. Reset and sequence the relay module.

5. If the fault persists, replace the relay module.

1. Check wiring; correct any errors.

2. Make sure the ﬂame ampliﬁer and ﬂame detector are compatible.

3. Remove the ﬂame ampliﬁer and inspect the connections. Reset the ampliﬁer.

4. Reset and sequence the relay module.

5. If the code reappears, replace the ﬂame ampliﬁer and/or the ﬂame detector.

6. If the fault persists, replace the relay module.

1. Inspect the jumper connections. Make sure the clipped jumpers were completely removed.

2. Reset and sequence the relay module.

3. If the fault persists, replace the relay module.

WARNING

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 78

Table D6: Blinking Fault Codes and Recommended Troubleshooting

Fault Code System Failure Recommended Troubleshooting

Code 5-1: Pre-ignition interlock

Code 5-2: High ﬁre switch or low ﬁre switch

Code 5-3: Manopen switch, start switch or control on

Code 6-1: Internal faults

Code 6-2: Internal faults

Code 6-3: Device speciﬁc

Code 6-4: Accessory fault

Cod 7-7: Unused Unused at this time.

Pre-ignition interlock fault.

Either high ﬁre switch or low ﬁre switch failure.

Man-open switch, start switch or control on in the wrong operational state.

Relay module self-test failure.

Fault with special OEM input circuits.

Unused at this time.

1. Inspect the jumper connections. Make sure the clipped jumpers were completely removed.

2. Reset and sequence the relay module.

3. If the fault persists, replace the relay module.

1. Check wiring and correct any errors.

2. Reset and sequence the relay module.

3. Use manual motor potentiometer to drive the motor open and closed. Verify at motor switch that the end switches are operating properly. Use run/test switch if manual potentiometer is not available.

4. Reset and sequence the relay module.

5. If the fault persists, replace the relay module.

1. Check wiring and correct any errors.

2. Make sure that the manual open valve switch, start switch and control are operating properly.

3. Stat switch held ‘On’ too long.

4. Reset and sequence the relay module.

5. Reset and sequence the relay module. If the fault persists, replace the relay module (RM7838A1014; RM7838B1013 or RM7838C1004 only).

1. Reset and sequence the relay module.

2. If fault re-appears, remove power from the device, re-apply power, then reset and sequence the relay module.

3. If the fault persists, replace the relay module.

1. Reset and sequence the relay module.

2. If fault re-appears, remove power from the device, re-apply power, then reset and sequence the relay module.

3. If fault does not repeat on the next cycle, check for electrical noise being copied into the relay module through the external loads or possibly an electrical grounding issue.

4. If the fault persists, replace the relay module.

1. Check wiring and operation of special OEM inputs.

2. Reset and sequence the relay module.

3. If fault re-appears, remove power from the device, re-apply power, then reset and sequence the relay module.

4. If the fault does not repeat on the next cycle, check for electrical noise being copied into the relay module through the external loads or possibly an electrical grounding issue.

5. If the fault persists, replace the relay module.

—

S89 Burner Control Module

Measure Flame Current

The S89 provides AC power to the ﬂame sensor which the ﬂame rectiﬁes to direct current. If the ﬂame signal back to the S89 is less than 0.8 µA, the S89 will shut down the system.

To measure the ﬂame current:

1. Connect a meter, set to the dc microammeter scale, in series with the ﬂame sensor as shown in Figure

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

D22. Use the Honeywell W136 Test Meter or equivalent. Connect the meter as follows: a. Disconnect the sensor lead at the S89. b. Connect the red (positive) meter lead to the S89

sense terminal.

c. Connect the black (negative) meter lead to the

free end of the sensor lead.

2. Restart the system and read the meter. The ﬂame sensor current must be at least 0.8 µA and steady.

Page 79

3. If the meter reads less than 0.8 µA or reading is unsteady, recheck points under Check Flame Sensor

and Igniter.

Flame sensor current check – use µA scale

To sensor

W136 (or equivalent)

Valve Valve (Gnd)

24V

24V (Gnd)

Gnd (burner)

Sense

Disconnect wire from sense terminal

Red (+)

multi-purpose meter

Black (−)

0.8 µA DC min. (and steady)

Figure D22: S89 ﬂame current measurement

Check burner flame condition

Operation

The S89 is powered by a 24V transformer. It operates in response to a call for heat from the thermostat.

On every call for heat, the S89 performs a safe start check. If a ﬂame or a ﬂame simulating condition is present, the S89 locks out without starting the igniter and must be reset.

Following the safe start check and, on the S89F, a valve on delay period, the S89 spark generator contacts close to energize the spark generator and the igniter. At the same time the gas control, powered through the gas valve relay contacts in the S89, opens so gas can ﬂow to the burner. The igniter is on during approximately the ﬁrst 80 percent of the ignition, or lockout timing, period. During the balance of the lockout timing period, the ignition is off and the ﬂame sensor attempts to prove the ﬂame. The ﬂame is proved when current from the ﬂame sensor through the burner ﬂame to ground reaches 0.8 µA dc.

If ﬂame is proved, the gas control remains open and the burner on until the call for heat ends.

Noisy lifting flame

Burner

Waving flame

Small blue flame

Lazy yellow flame

Good rectifying flame

¼–½” [6.4–12.7 mm]

1” [25.4 mm]

Check for:

• High gas pressure

• Excess primary air or draft

Check for:

• Poor draft

• Excess draft

• High velocity or secondary air Install shield if necessary

Check for:

• Clogged ports or orifice filter

• Wrong size orifice

Check for lack of air from:

• Dirty primary air opening

• Large ports or orifices

If ﬂame is not proved, the gas control closes and the system is locked out until the S89 is reset.

If ﬂame is lost after being proved, the S89 will close the gas control, perform a safe start check, and, on the S89F, valve on delay, then return ignition as described above.

The S89 is reset by turning the thermostat below room temperature or removing power to the system for 45 seconds.

Start

Safe start check

Valve on delay (S89F only)

Trial for ignition

Burner operation

End

1. Thermostat calls for heat.

2. Safe start check.

2A. Valve on delay (S89F only) combustion air blower starts.

3. Spark generator powered. Ignition begins and gas control opens.

4. Burner lights. Ignition stops and flame current is sensed.

5. Burner runs, S89 monitors flame current.

6. Thermostat satisfied. Gas control closes, burner goes off.

Power interruption. System shuts off. Restarts when power is restored.

If flame simulation condition is present, system will not start.

If no spark, S89 locks out and shuts down system. Must be reset.

If flame current is absent, weak or unsteady, S89 locks out and shuts down system. Must be reset.

If flame is lost, S89 closes gas control, then restarts safe start check and trial for ignition.

Figure D23: Check burner ﬂame condition

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Figure D24: Normal sequence of operation

Page 80

Troubleshooting

WARNING

Fire or explosion hazard. Can cause severe injury, death, or property damage.

Any replacement S89 must have the same or shorter lockout timing and the same or longer delay timing as the original control.

IMPORTANT

1. The following service procedures are provided as a general guide. Follow Appliance Manufacturer service instructions, if available.

2. All meter readings must be taken within the trial for ignition period. Once the ignition period ends, the system must be reset by setting the thermostat down for at least 45 seconds before continuing.

3. If any component does not function properly, make sure it is correctly installed and wired before replacing it.

4. The ignition module cannot be repaired. If it malfunctions, it must be replaced.

5. Only trained, experienced service technicians should service direct spark ignition systems.

Before beginning troubleshooting, review the normal operating sequence of the S89. See the Operation section. Then follow the steps in Fig. 5 to identify the source of the problem. Some steps are explained in greater detail below.

Besides standard hand tools, you will need the following to complete the troubleshooting:

1. Honeywell W136 Test Meter or equivalent.

2. Test lead – A length of ignition cable or other heavily insulated wire with both ends stripped ½” [13 mm].

Check Ignition System Grounding

Nuisance shut downs are often caused by a poor or erratic ground.

A common ground is required for the module, igniter, ﬂame sensor and main burner.

1. Check for good metal-to-metal contact between the igniter bracket and the main burner.

2. Check the ground lead from the GND (burner) terminal on the module to the igniter bracket. Make sure connections are clean and tight. If the wire is damaged or deteriorated, replace it with 14 to 18 gauge, moisture resistant, thermoplastic insulated wire with a 221°F [105°C] minimum rating. Use a shield if necessary to protect the ground wire from radiant heat.

Check Spark Ignition Circuit

The S89 spark generator relay switches 120 VAC to the remote mounted spark generator, which, in turn, powers the spark igniter at the burner. Check as follows:

1. Shut off gas supply to the gas control.

2. Disconnect the ignition cable at the spark generator stud terminal.

3. Set the thermostat to call for heat.

4. Reset the S89 by removing power to the module for 45 seconds.

WARNING

Electrical shock hazard. Can cause severe injury, death, or property damage.

In the next step, do not touch either the stripped end of the test lead or the stud terminal.

5. Restore power. Before the S89 locks out, touch one end of the test lead ﬁrmly to the S89 GND terminal. Do not remove the existing ground lead.

6. Slowly move the other end of the test lead toward the stud terminal on the spark generator until sparking stops.

7. Slowly pull the wire away from the stud terminal and note the size of the gap when sparking stops.

8. Follow instructions in Table D7.

Table D7: Spark Ignition Troubleshooting

If the gap was Then

1/8” [3 mm] or more Generator output voltage is okay.

Less than 1/8” [3 mm] or

no spark

Check Flame Sensor and Igniter

1. Make sure burner ﬂame is capable of providing a good rectiﬁcation signal. See Figure D23.

2. Make sure about ¾” to 1” [19 to 25 mm] of the ﬂame sensor is continuously immersed in the ﬂame for best ﬂame signal. See Figure D23. Bend the bracket or ﬂame sensor, or relocate the sensor as necessary. Do not relocate the igniter.

3. Make sure ﬂame does not touch sensor or ignitor ceramic insulator and that insulators are below he ﬂame. Excessive heat (over 1,000°F [538°C]) will cause short to ground. Move sensor to cooler location or shield insulators if excessive heat is suspected. Do not relocate the igniter.

4. Check for cracked igniter or sensor ceramic insulator, which can cause short to ground, and replace unit if necessary.

5. Make sure electrical connections are clean and tight.

6. Replace damaged wire with moisture resistant number 18 wire rated for continuous duty up to 221°F [105°C].

Check for 120 VAC at the spark gen-

erator terminals. If okay, replace the

spark generator.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 81

Start

Review normal operating sequence. Turn gas supply on. Turn thermostat up to call for heat.

Power to S89 (24 VAC and 120 VAC Normal).

Yes

S89E – 10 second max. Delay for safe start check.

S89F only – 38 second max. Valve-on delay.

Yes

Spark across igniter gap.

Yes

Main burner lights.

Yes

Spark stops before end of igniter timing.

Yes

System runs until call for heat ends.

Yes

Check line voltage power. Low voltage transformer, limit controller, thermostat and wiring. Also, air proving switch on pre-purge systems (see wiring hookups).

Replace S89.

Check spark ignition circuit. See component checks.

Spark ok?

• Check for 120V to spark generator.

• Replace spark generator if voltage ok.

• If no voltage, replace S89.

Yes

Make sure ignition cable:

• Provides electrical continuity.

• Does not touch any metal surfaces.

• Connections are metal surfaces.

• Shows no signs of melting or buckling. Replace and shield cable if necessary.

Make sure burner spark igniter and S89 ground (burner) terminal have effective common ground. Poor or erratic ground will cause nuisance shutdowns.

Check for cracked insulator on igniter or flame sensor. Replace device with cracked insulator to prevent short to ground.

Note: If S89 locks out, reset before continuing.

• Check for 24 VAC across valve and valve (ground) terminals on S89. If no voltage, replace S89.

• Make sure igniter and sensor are properly positioned. See component checks.

• Check electrical connections between S89 and gas control. If ok, replace gas control.

Replace S89.

Note: If S89 locks out, reset before continuing.

• Make sure flame current is at least 0.8 micro amps. See component checks.

• Make sure L1 and L2 are connected to the proper terminals.

• Make sure flame does not touch sensor insulator and that sensor insulator is below flame. Excessive heat (over 1,000ºF [538ºC] will cause short to ground. Relocate sensor or shield insulator if excess heat is suspected.

• If checks are ok, replace S89 module.

Call for heat ends; system shuts off.

Yes

Troubleshooting ends.

Figure D25: Troubleshooting S89E,F

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

• Check for proper temperature controller operation.

• Remove valve lead at S89; if valve closes, recheck temperature controller and wiring. If not, replace gas control.

Repeat procedure until trouble free operation is obtained.

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VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 83

Appendix E: EnergyPack®, ERV5000–10000(i/e) and

HRV3000–10000(i/e) Start-up Form and Checklist

IMPORTANT

• Complete all forms under this appendix for each unit and email, fax or mail to Venmar CES immediately after start-up to validate warranty and to provide valuable information for personnel performing future maintenance or for factory assistance to address below.

• Read the Installation, Operation and Maintenance Instruction Manual and the Venmar CES Control System Keypad Operation Guide and the Sequence of Operation before proceeding.

• Leave a copy of this report with the owner and at the unit for future reference and permanent record.

• To ensure proper operation of each unit, qualiﬁed personnel should perform the start-up, complete the checklist and report.

• All units are functionally tested except when shipped in multiple pieces. Start-up adjustments may be required. If the unit is shipped as a single piece, blowers, enthalpy wheel and compressors (if equipped) are set up to run correctly when power is connected. If any blower is running backwards or compressor is making loud noises, disconnect power and switch two leads (on three-phase power) to ensure proper rotation and avoid damage.

• If units are equipped with compressors, power must be turned on for 24 hours prior to a call for cooling, for the compressor crank case heaters to be energizing to prevent possible damage.

• The Bacview keypad located at the control panel will allow for manual override for start-up, mode of operation selection and includes an internal time clock if remote interlocks are not provided.

Venmar CES Inc. 200 Rue Carter St. Léonard d’Aston, QC Canada J0C 1M0

Email to tech support: venmarservice@venmarces.com Fax: 899-319-2612 Phone: 1-866-4-VENMAR

Unit Identiﬁcation Information

Project ____________________________________________ Job Name _________________________________________ Job Address __________________________________________________ __________________________________________________ __________________________________________________ Model Number _____________________________________ Serial Number ______________________________________ Tag ______________________________________________ Jobsite Contact ____________________________________ Email _____________________________________________ Telephone _________________________________________

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 84

Serial Number: _____________________________________

Table E1: Pre Start-up Checklist

Checklist Item Check √ N/A

1 Check the electrical disconnect set to the ‘Off’ position. 2 Check the split section joints are properly installed on multi-sectional units.

Check that all holes that have been made by the Installing Contractor after receiving the unit in the

casing, partitions or ﬂoor have been well sealed to prevent air and/or water inﬁltration. Check the unit for obstructive packaging, objects near or in fans, dampers, energy recovery wheel, etc.

a. Check that the inside of unit has been cleaned of all debris. Remove all retaining bolts on fan isolation bases. a. Check that the fan impellers are rotating freely. b. Check fan impellers and drive set screws. Tighten if required.

c. Check the fan bearing set screws or locking collars. Tight if required. d. Check fan belt alignment and tension. e. Check the fan ﬂexible joint connections are well attached.

Check that the air ﬁlters are installed and clean. Replace if necessary. See Appendix F for optional downstream high efﬁciency HEPA ﬁlter installation (if supplied).

a. Check all face mounted ﬁlters are attached with four clips each.

b. Check each sliding ﬁlter has a retainer at the end track and well attached blank-offs. c. Check the ﬁlter pressure differential gauges, switches or sensors are free of dirt and set at a

value satisfactory to the end user to trigger a ﬁlter change. Check coils if ﬁns have been damaged in shipping, installation or building construction and are clean. Straighten ﬁns with a ﬁn comb and clean coil if required.

a. Check all pipe connections are tight and that no damage has occurred during shipping or installation. b. Check that the piping to the coils and WSHP have been completed, piping lines have been

ﬂushed, ﬁlled, vented and tested at 1.2 times the operating pressure. Refer to Appendix B. Scroll compressor RIS vibration isolator bolts are factory tightened to the correct torque setting for operation and do not require ﬁeld adjustment. a. Check the refrigerant components and piping are in good condition and have no damage or

leaks from shipping or installation. b. Check that the refrigerant lines are spaced at least 1” apart and from the compressor after ship-

ping and installation. c. Check that the refrigerant line clamps are still secure and have their rubber lining. d. Check that the clearance around the air cooled condenser is within minimum clearance and the

discharge is not blocked. Check motorized damper control arms, control rods and shafts for tightness.

a. Check that non motorized dampers rotate freely. Check the energy recovery wheel media for any defects from shipping or installation. See

nance section for details.

a. Grease both pillow block bearings on the wheel(s) when grease nipples provided. b. Check that the wheel(s) are turning freely by hand and do not bind.

c. Visually inspect the wheel(s) to ensure it is centered and does not tilt. If there is any indication of

11 Check the plate media for any defects from shipping or installation.

a problem call Venmar CES Tech Support at 1-866-4-VENMAR. d. Check that the wheel seals are properly positioned from the face of the wheel.

e. Check that the wheel purge (if present) is set to the default angle as speciﬁed in the submittal. f. Check the mounting fasteners on the wheel(s) motor and gear reducer are tight. g. Check the belt and pulley on the wheel drive for correct alignment, tension and set screw tightness.

Mainte-

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 85

Serial Number: _____________________________________

Table E1: Pre Start-up Checklist

Checklist Item Check √ N/A

Check the heat pipe ﬁns for any ﬁn defects from shipping or installation. a. Remove retaining bolts on heat pipe tilt mechanism.

b. Check the heat pipe ﬂexible connection is properly attached and sealed on tilt mechanism. c. Check the actuator control arm and linkages are tight on tilt mechanism.

13 Check that ductwork is connected, complete and free of obstructions. 14 Check that condensate drain connections have been trapped, installed correctly and ﬁlled.

Check at all unit split sections that all factory internal high and low voltage wiring connections have

been properly re-connected.

16 Check that all shipped loose or ﬁeld supplied components have been correctly installed and wired. 17 Check that the wiring diagram has been marked up accordingly and left with the unit.

Check that all power supplies and control wiring have been inspected and approved by the Local

Authorities having jurisdiction.

19 Check all factory and ﬁeld wiring connections for tightness. Tighten if necessary. 20 Check that all fuses are properly installed in holders.

Check the voltage at the disconnect switch against the nameplate and against phase-to-phase

readings on three-phase. If the voltage is not within 10% of rated or 2% of phase to phase, have the condition corrected before continuing start-up. Check that all ﬁeld piping and venting installation and connections for heating and cooling options

have been completed and tested.

23 Set the heating and cooling enable switches to the ‘Off’ position.

Refer to Appendix D for gas-ﬁred furnace module and Appendix G for electric coil installation and

maintenance and check that the installation is completed. Perform all gas-ﬁred furnace and electric coil pre start-up checks.

25 Check that all safety switches, overloads or other manual reset devices are reset.

If the unit is equipped with compressors, power must be turned on with the unit in ‘Off’ mode for

24 hours before start-up. This will energize crank case heaters and assure no liquid refrigerant is present which could cause compressor damage or failure. Check that this has been completed.

Table E2: Start-up Checklist

Checklist Item Check √ N/A

1 Before proceeding, complete the pre start-up checklist.

2 Check that all access panels or doors are closed.

If units are equipped with compressors, feel the compressor crank cases. They should be warm if the disconnect has been ‘On’ for at least 24 hours. This will assure that no refrigerant liquid is

present in the crank case which could cause compressor damage or failure to occur on start-up. Otherwise, turn the main disconnect to the ‘On’ position. The unit can be started by using the keypad and selecting the mode of operation from the Keypad Operation Guide and the Sequence of Operation. Disable the heating and cooling functions and

set the unit to the occupied mode to bump start the fan wheel(s) and energy recovery wheel(s) to check their operation.

5 Check that dampers are operating properly.

6 Check that the fan wheel(s) and energy recovery wheel(s) are rotating in the correct direction.

7 Adjust the fan motor VFD(s) to the correct air volume/Hertz.

For occupied recirculation mode, adjust outside, exhaust and mixed or recirculation air damper

positioners to achieve the required air volumes. Check amperage draw to each motor on each phase against motor nameplate FLA. If signiﬁcantly

different, check ductwork static and/or take corrective action.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 86

Serial Number: _____________________________________

Table E2: Start-up Checklist

Checklist Item Check √ N/A

Recheck the voltage at the disconnect switch against the nameplate and against phase-to-phase

readings on three-phase with all blowers operating. If the voltage is not within 10% of rated or 2% of phase-to-phase have the condition corrected before continuing start-up. Before activating the compressor on WSHP units, check that the water shut-off valves are open and

water is circulating through the water-to-refrigerant heat exchanger. Check the incoming line water pressure to ensure is within design and acceptable limits. Enable the cooling mode of operation. Check if the sound of the compressor is normal or if there is

excessive vibration. On units with integrated air cooled condensers check condenser fans are rotating in the correct

direction.

14 Check all ﬁeld and factory refrigerant and water piping connections for leaks and correct.

Operate the refrigerant system near full load conditions in both heating and cooling modes and check sub-cooling and superheat against values in Appendix P, Table P1. If readings do not match,

adjust the refrigerant charge. Refer to Appendix P for information on adjusting the refrigeration charge.

On units with WSHP, after a few minutes of operation: a. Check the supply discharge temperature status on the keypad for cooling air delivery. Measure

the temperature difference between entering and leaving water. In cooling mode, the tempera-

ture difference should be approximately 1.5 times greater than the heating mode temperature

difference. For example, if the cooling temperature difference is 15°F [8.3°C], the heating

temperature difference should be approximately 7°F to 10°F [3.9°C to 5.6°C]. Alternatively, if a

20 Check the operation of the control options provided on the unit.

21 Check the setpoints on the DDC Points Reference, adjust and record changes as required.

22 Has air balancing been completed for both occupied and unoccupied operation?

flow measuring valve or pressure gauge connections are included, take the flow reading or pres-

sure drop compared to the submittal information and adjust the shut-off/balancing valve in the

return line to the correct flow/pressure drop reading. b. Measure the temperature difference between entering and leaving air and entering and leaving

water. With entering water of 60°F to 80°F [15.6°C to 26.7°C], leaving temperature should

rise through the unit. Should not exceed 35°F [19.4°C]. If the air temperature exceeds 35°F

[19.4°C], then the water flow rate is inadequate or the airflow rate may be low and a second

check may be required after air flow balancing. On units with gas-ﬁred furnace module or electric heating coils, check supply air proving interlock switch setting to ensure minimum supply airﬂow prior to burner operation. Set the switch to open below the minimum supply airﬂow on the furnace rating plate. Enable heating options, see start-up and check out instructions in Appendix D for gas-ﬁred furnace module and Appendix G for electric coil and complete. For electric heating coil option check the amp draw on each stage, the operation of the sequence or SCR controller and the coil for any hot spots.

When unit has achieved steady state, take measurements and complete Start-up Readings portion of the Start-up Report and Checklist in Appendix E. Send a copy of the completed Start-up Report

and Checklist to Venmar CES to validate warranty. Maintain a copy of the report at the unit for future reference. Once completed, return setpoints to original or required values, return the unit to the correct mode of operation and adjust the time clock if required.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 87

Serial Number: _____________________________________

Start-up Readings

• Allow unit to reach steady state before taking readings.

• Complete based on options included with unit

Nameplate voltage

Input voltage L1–L2 L2–L3 L1–L3

Table E3: Start-up Readings – Supply Fan

Amp Draw

O/L Amp

Setting

Fan 1

Fan 2

Fan 3

Fan 4

Fan 5

Fan 6

Fan 7

Fan 8

Fan 9

Fan 10

Fan 11

Fan 12

Rotation

Correct

Full Load Amps

(Nameplate Amps)

L1 L2 L3

Hertz RPM

Table E4: Start-up Readings – Exhaust Fan

Rotation

Correct

Fan 1

Fan 2

Fan 3

Fan 4

Fan 5

Fan 6

Fan 7

Fan 8

Fan 9

Fan 10

Fan 11

Fan 12

Full Load Amps

(Nameplate Amps)

Amp Draw

L1 L2 L3

O/L Amp

Setting

Hertz RPM

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 88

Table E5: Start-up Readings – Condenser Fan

Rotation Correct

Fan 1

Fan 2

Fan 3

Fan 4

Fan 5

Fan 6

Fan 7

Fan 8

Fan 9

Fan 10

Fan 11

Fan 12

Fan 13

Fan 14

Fan 15

Fan 16

Full Load Amps

(Nameplate Amps)

Serial Number: _____________________________________

Amp Draw

L1 L2 L3

O/L Amp Setting

Table E6: Start-up Readings – Compressors

Full Load

Amps

(Nameplate

Amps)

Compressor 1

Compressor 2

Compressor 3

Compressor 4

Compressor 5

Compressor 6

Compressor 7

Compressor 8

Compressor 9

Compressor 10

Compressor 11

Compressor 12

Compressor 13

Compressor 14

Compressor 15

Compressor 16

Amp Draw

L1 L2 L3

After compressor has been running for 15 minutes check the

following:

Suction

Pressure

Discharge

Pressure

Superheat

Liquid

Subcooling

Hot Gas

Bypass

Functioning

Outdoor

Ambient Temp.

During AC

Cooling

Start-up (°F/°C)

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 89

Table E7: Start-up Readings – WSHP

Waterside Cooling Mode Waterside Heating Mode

Entering

Temp. (°F/°C)

Condenser 1

Condenser 2

Condenser 3

Condenser 4

Condenser 5

Condenser 6

Condenser 7

Condenser 8

Condenser 9

Condenser 10

Condenser 11

Condenser 12

Condenser 13

Condenser 14

Condenser 15

Condenser 16

Leaving

Temp.

(°F/°C)

Temp.

Difference

(°F/°C)

Entering

Temp.

(°F/°C)

Serial Number: _____________________________________

Leaving

Temp.

(°F/°C)

Temp.

Difference

(°F/°C)

Entering Pressure

(PSI)

Leaving Pressure

(PSI)

US GPM

Table E8: Start-up Readings – Electric Heating Coil

Stage L1 Amps L2 Amps L3 Amps Check for Hot Pots

Table E9: Start-up Readings – Energy Recovery Wheel (ERW)

Full Load Amps

(Nameplate Amps)

ERW 1

ERW 2

ERW 3

ERW 4

L1 L2 L3

Amp Draw

O/L Amp Setting

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 90

Serial Number: _____________________________________

Table E10: Start-up Readings – Gas-ﬁred Duct Furnace

Fuel Natural Gas Propane Furnace #1 Furnace #2

Rotation correct

Combustion air fan

Full load amps (nameplate amps) Amp draw L1/L2/L3 O/L amp setting Rotation correct

Induced draft fan motor

Full load amps (nameplate amps) Amp draw L1/L2/L3 O/L amp setting Inlet gas pressure – ” w.c. Regulator outlet pressure – ” w.c. Manifold press – ” w.c. Stack CO2 – % Stack O2 – %

Low ﬁre

Net stack temperature – °F/°C Efﬁciency – % Flame signal – mA/VDC Supply air inlet temperature – °F/°C Supply air discharge temperature – °F/°C Supply air temperature rise – °F/°C Inlet gas pressure – ” w.c. Regulator outlet pressure – ” w.c. Manifold press – ” w.c. Stack CO2 – % Stack O2 – %

High ﬁre

1. Measure downstream where temperature is even in duct.

2. For IG series drum and tube gas-ﬁred duct furnace models only.

This unit has been checked out and started according with the above procedures and completed forms and is operating satisfactorily. After 24 hours of satisfactory operation shut down the unit and check all foundation bolts, shaft bearings, drive set screws, valve train and terminals. Tighten where required.

Additional Comments: __________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Start-up

By ________________________________________________ Company Name ____________________________________ Date ______________________________________________ Email _____________________________________________

Telephone _________________________________________

Email to tech support: venmarservice@venmarces.com or Fax to: 819-399-2612.

Page 91

Appendix F: HEPA Filter Installation

These instructions are for installing AAF HEPA ﬁlters (11½” depth) into AAF HEPA holding frames. The holding frames are available in multiple sizes and materials, but include the PN series of 30619XX-XXX, where the X’s vary with frame size and material. All frames, latches, extension legs and ﬁlters are sold separately. Please read the entire installation instructions before beginning the installation process.

Install ﬁlters into the HEPA holding frames only after the frames have been securely installed into existing ductwork or housing. Frames should be bolted or pop riveted together into the permanent structure through the predrilled holes around the outside perimeter of the frames. Frames should be sufﬁciently caulked and sealed to prevent any air bypass or leakage.

Required Tools for Filter Installation

• T-handle Hexkey, size 5/32”

Framing Components Required

• AAF HEPA holding frames – PN 30619XXXXX

• Leg extensions, four per frame – PN 3061991- 00X

• Latches, four per frame – PN 3062007-00X

Figure F3: Frame with leg extensions installed

Step 2

Insert the HEPA ﬁlter into the HEPA holding frame. The HEPA should be installed with the gasket side of the ﬁlter facing the frame. Insert the ﬁlter as far into the frame as possible, so that the gasket material is contacting the frame. See Figure F4 below.

Figure F1: Leg extensions and latches

Step 1

At the inside corner of each frame are four tabs, two per side. Place a leg extension over the four tabs as shown in Figure F2 below, then pull back on the leg extension locking it into place.

Figure F2: Place leg extensions over the frame tabs, then pull back to lock the leg extension into place

Repeat Step 1 with each of the four corners. The frame with leg extensions should look like Figure F3.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Figure F4: Insert HEPA ﬁlter into frame, until the gasket comes in contact with the holding frame

The ﬁlter should now be resting inside of the holding frame as shown to the left. When installing the ﬁlters into

Page 92

a frame bank of multiple frames, install the lower ﬁlters ﬁrst so that the upper ﬁlters can rest on the lower ﬁlters.

Figure F5: Filter placed inside of frame

Step 3

Place a latch so that it overlaps the leg extension, as shown below in Figure F6. Align the latch’s cap screw with the threaded coupling on the end of the leg extension and tighten using the hexkey. Tighten the cap screw until there is an approximately ¼” gap between the latch and the leg extension coupling as shown below in Figure F7. Repeat this step with all four corners.

Step 4

Once all four corner latches have been tightened within ¼” of the leg extension coupling, complete the installation by tightening each corner until the latch and leg extension coupling meet. This is illustrated in Figure F8.

Figure F8: Tighten until latch and coupling meet

Once all four corners have been tightened the ﬁlter should now be properly seated and sealed.

Repeat the process with all remaining ﬁlters working from the bottom to the top.

Figure F6: Latch overlapping leg extension

Figure F7: Tighten cap screw to ¼” of the coupling

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Figure F9: Properly installed ﬁlter

Page 93

Appendix G: Electric Heating Coil and Controls Information

This electric heating coil module covered by this appendix is a component of a “Listed” product, subject to the guidelines of application as designated by the Certifying Agency and outlined in the appliance Manufacturer’s installation and operation instructions.

The information provided in this appendix applies to the electric heating coil module, installed in the appliance and to its operation, maintenance and service. Refer to the appliance manufacturer’s instructions for information related to all other components.

1 – Mechanical Installation of Electric Coil Heaters

1.1 Handling

1.1.1 Remove the shipping covers just before installation.

1.1.2 Inspect the heater carefully and report any damage to the manufacturer.

Do not install a damaged heater.

1.2 Installation

Heater Position

1.2.1 The axis of the duct must always be perpendicular to the face of the heater.

1.2.2 The heating elements must always be installed horizontally.

Model SC or ST (Slip-in Type)

1.2.3 Cut an opening in the side of the duct.

1.2.4 Slip the heater into the duct until the hole is completely covered by ﬂanges around the heater.

1.2.5 Fasten the heater to the duct with sheet metal screws and seal openings with a suitable sealing compound.

1.2.6 If the heater is heavy, use additional hangers to support the heater.

Model FC or FT (Flanged Type)

1.2.7 Flange both ends of the duct outwards on three sides to match the heater’s ﬂanges.

1.2.8 Fasten the heater to the duct with sheet metal screws (for heavy heaters, use nuts and bolts and additional hangers to support the heater).

1.2.9 Seal openings with a suitable sealing compound.

2 – Electrical Installation of Electric Coil Heaters

2.1 Disconnect Power Source

Disconnect all power sources before opening the control box and working within.

2.2 Read Nameplate

Read the nameplate carefully and consult wiring diagram before starting to wire.

2.3 Supply Wires

Use only wires suitable for 167°F [75°C]. Wires shall be sized according to the Canadian Electrical Code requirements. All wires must be brought in through knock-outs.

2.4 Disconnecting Means

Install a disconnect switch close to the heater according to the code unless a disconnect switch is already built into the heater.

2.5 Control Circuit Wiring

Use Class 2 wiring for control circuit connections to the duct heater.

2.6 Magnetic Contactors

If magnetic contactors are mounted outside of the duct heater, use only contactors approved for:

• 250,000 operations when controlled by auto-reset thermal cut-out (A) and by other switching devices in series with this cut-out (thermostat, step controller, airﬂow switch, etc.).

• 100,000 operations when controlled by auto-reset thermal cut-out (A) alone.

• 100,000 operations when controlled by auto-reset thermal cut-out (A) plus manual reset cut-out in series (A & M).

• 6,000 operations when controlled by manual reset cutout (M) alone.

2.7 External Controls Ratings

Rating of external control devices shall be suitable for handling the VA ratings as marked on the nameplate; otherwise, a backup relay must be used.

IMPORTANT

• Do not install spray humidiﬁers upstream of duct. Install it downstream instead.

• Do not cover the control box with thermal insulating materials.

• Use special air intake louvers of weatherproof construction for preheat duct heaters to avoid intake of water or snow particles.

• Make sure that motorized damper blades are not blocked with snow or dirt. Inspect the dampers regularly to ensure a suitable airﬂow.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

2.8 Airﬂow Interlock

Heaters are generally supplied with one extra terminal marked for fan interlock or air sensing device connection. Remove jumper between terminals I and C before connecting the fan interlock. Select a suitable airﬂow sensing device of the differential pressure sensing type, with snap acting contacts. A slow make, slow brake device may cause undue cycling and in some instances chattering of the contactors. When fresh air dampers are used, make sure the heater is properly interlocked to prevent it from being energized before the damper is fully open.

Page 94

3 – Operating Electric Coil Heaters

3.1 Minimum Airﬂow

Ensure that sufﬁcient airﬂow as marked on the nameplate is passing through the heater. Airﬂow should be evenly distributed across the entire face of the heater. Use air turning vane at duct elbows and splitter damper at duct branchoffs to streamline the airﬂow in the heater. Use suitable airﬂow sensing device or interlock the heater with fan. An insufﬁcient airﬂow will lead to the opening of the autoreset thermal cut-out or damage to the heating elements.

3.2 Warning

The air ﬂowing through the duct where the heater is installed shall not contain any combustible particles, nor any ﬂammable vapor or gas.

3.3 Air Temperature

The air temperature should not exceed 120°F [49°C] at the heater outlet.

3.4 Minimum Static Pressure and Air Direction

The heater is protected by a differential pressure switch. To keep the contact of this switch closed, it is necessary to maintain a minimum total pressure of 0.07” of water for a constant ﬂow.

3.5 Manual Reset Thermal Cut-out

This protection device is standard on all heaters of less than 300 volt and 30 kW and is optional on all other heaters. Please check the auto-reset thermal cut-out before resetting the manual thermal cut-out. If any defect has been detected in the auto-reset thermal cut-out, it will be necessary to replace it before resetting the manual reset thermal cut-out.

4.2 Electrical Inspection

Two weeks after start-up, all electric connections to contactors should be checked and tightened up. Before each heating season, check the resistance between the heating elements and ground. It is also recommended to check the electrical connections to heating elements, magnetic contactors and main power lugs. This inspection is recommended monthly during the ﬁrst four months of operation. After that, two inspections per heating season are sufﬁcient.

4.3 Checkpoints

• Check all fuses.

• Check the resistance to ground for each circuit.

• Check the resistance phase-to-phase for each circuit.

• Check the tightening of connections at all contactors and heating elements.

• Check all contactors.

4.4 Off-season Maintenance

Where tubular heating elements are used, it is strongly recommended that you start the heating system from time to time. This precaution will prevent moisture from percolating through the terminal gaskets into the heating element and accumulating in the insulating powder. Should a heater be shut off for a long period, we recommend that you check carefully the resistance to ground for each circuit. It is important not to power a heater when too low a resistance to ground has been measured. It is also recommended to pay attention to any other heater operating in normal conditions. Control components such as step controllers or modulating valves (SCR) should be maintained and checked according to respective Manufacturer’s instructions. Any defective components should be replaced only with identical original parts.

4 – Maintenance

All electric coil heaters have been designed to operate long term without problems. Those responsible for equipment and maintenance should be aware of the following suggestions.

4.1 Visual Inspection

It is strongly recommended to complete a periodic inspection. This precautionary step will help to keep your installations operating well. Note these eventual ﬁrst signs of problems:

• Accumulation of dust on the heating elements.

• Signs of overheating on the heater frame.

• Traces of water or rust on the control box.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 95

Appendix H: Extended Dormant Unit Maintenance Procedure

The following procedures must be applied to any unit which is stored for a period exceeding one month, which are required in order to maintain our warranty. Failure to comply with the procedures outlined below may result in damage and will void unit warranty.

1. Unit must be stored indoors in a clean, dry and tempered environment, heated in the winter and air cooled in the summer. Ambient air conditions should be from 50°F to 75°F with % RH from 10% to 50%. The unit needs to be stored in a warehouse (or some type of enclosure). Storing units outdoors is con-

traindicated and will void our warranty.

2. Unit must be stored on a level surface with the weight of the equipment evenly distributed through its base. The unit location must be free from excessive vibration and accidental impacts.

3. Once the unit has been unloaded in its resting location, the plastic wrapping must be removed from the unit by cutting along the corner edges in order to perform proper inspections and maintenance on the equipment. The plastic wrapping should be kept and re-applied to the unit when the unit will ﬁnally be shipped to the jobsite.

4. If applicable, a certiﬁed/qualiﬁed Refrigeration Technician should record refrigerant pressures on all compressors at time of storage. Each compressor must maintain refrigerant pressure in the system.

5. If applicable, a certiﬁed/qualiﬁed Refrigeration Technician should check refrigerant pressure in each compressor every three months. Refrigerant pressure must be maintained in the system. If zero pressure is found, this indicates a leak in the system. Leak(s) must be identiﬁed and repaired. A holding pressure must then be reinstalled.

6. Rotate blower impellers by hand every two months; grease fan bearings as required following proper practices. Do not over grease the bearings as this may rupture the seals and lead to premature bearing failure during operation.

7. Rotate the energy recovery wheel rotor by hand once per month.

8. Ensure that all unit doors are kept closed.

9. Continue above maintenance schedule until unit start-up.

For all checks listed above please complete the Extended Dormant Unit Maintenance Checklist below and send a copy to the Venmar CES service department every six

months and when unit is put into service.

If the unit has been dormant for an extended period after initial start-up, all start-up checks should be repeated before operating the unit. Refer to the EnergyPack Start-up Report and Checklist in Appendix E and complete these checks. Failure to comply with the above recommendations may result in component failure and surface corrosion on the interior and exterior of the unit.

Please note that if the unit is being stored outdoors or remains dormant for an extended period after initial startup, this may result in condensation within the unit which could result in premature degradation of the unit and potential issues within the control panel. In this event, the installation of a desiccant pouch in the control cabinet is highly recommended; all ventilation ducts should be capped/covered to prevent chimney effect, all liquid pipes (water or glycol mixture) should be drained or capped off if necessary and all peripheral electrical penetrations should be properly sealed.

IMPORTANT

• Complete the Extended Dormant Unit Maintenance Checklist below, send a copy to Venmar CES service department at the below email address or fax every six months and when unit is put into service, to validate warranty and to provide valuable information to personnel performing future maintenance or for factory assistance.

• Leave a copy of this report with the owner and at the unit for future reference and permanent record.

Additional Comments: ______________________________ __________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Email to tech support: venmarservice@venmarces.com Fax: 899-319-2612

Unit Identiﬁcation Information

Project ____________________________________________ Job Name _________________________________________ Job Address _______________________________________ Model Number _____________________________________ Serial Number _____________________________________ Tag ______________________________________________ Jobsite Contact ____________________________________ Email _____________________________________________ Telephone _________________________________________

Maintenance

Telephone _________________________________________

Page 96

Serial Number: _____________________________________

Table H1: Extended Dormant Unit Maintenance Checklist

Item Description Yes No

Is the unit stored indoors in a clean, dry environment?

Recommend Has a desiccant pouch been placed in the control panel?

Item Description Inspection Date/Reading

Is the unit storage facility temperature regulated to within 50°F to 75°F?

Is the indoor storage facility humidity regulated to within 10% to 50% RH? Is the unit mounted on a level surface along the perimeter of the base with weight evenly

distributed? Has the plastic wrapping been removed from the unit to perform inspection and maintenance?

Has the plastic wrapping been saved for future use? Has the plastic wrapping been re-applied to the unit when the unit has been shipped to

jobsite?

Refrigerant pressure at storage

Date PSIG

Compressor 1

Compressor 2

Compressor 3

Compressor 4

Compressor 5

Compressor 6

Compressor 7

Compressor 8

Compressor 9

Compressor 10

Compressor 11

Compressor 12

Compressor 13

Compressor 14

Compressor 15

Compressor 16

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 97

Serial Number: _____________________________________

Table H1: Extended Dormant Unit Maintenance Checklist

Item Description Yes No

Refrigerant pressure every three months

Compressor 1

Compressor 2

Compressor 3

Compressor 4

Compressor 5

Compressor 6

Compressor 7

Compressor 8

Compressor 9

Compressor 10

Compressor 11

Compressor 12

Compressor 13

Compressor 14

Compressor 15

Compressor 16

Rotate blower impellers every two months

Supply

Exhaust

Other Grease fan bearings as

required Supply

Exhaust

Other

Rotate energy recovery rotor every one month

Enthalpy

Sensible

Date PSIG Date PSIG Date PSIG

Date Date Date Date Date Date

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 98

Appendix I: EnergyPack®, ERV5000–10000 and HRV3000–10000

Maintenance Summary Chart

Table I1: Maintenance Summary Chart – EnergyPack, ERV5000–10000, HRV3000–10000

Item No. Description Note Monthly Quarterly

1 Inspect the general condition of the unit. x

General

Fans

Dampers

Air ﬁlters

Coils

Wheel

Plate heat exchanger

Burner

Electric

Condenser fans

Cooling section

2 Remove any dirt or debris. x

3 Check for unusual noise or vibration. x

4 Lubricate the door latch mechanisms. x

5 Clean fans with stream of water. x

6 Align or replace belts and drives. x

7 Adjust belt tension. x

8 Check motor voltage and current. x

9 Lubricate the motor and shaft bearings. x

10 Lubricate motor base adjusting screws. x

11 Visual inspection for dirt or leakage. x

12 Lubricate damper linkage. x

13 Clean and replace preﬁlters. x

14 Clean and replace ﬁnal ﬁlters. x

15 Inspect holding frames/sliding rack. x

16 Clean the coils. x

17 Winterize the water coil. x

18 Verify that the wheel is rotating freely. x

19 Lubricate bearings. x

20 Inspect bearing bolts. x

21 Tighten bearing set screws. x

22 Tighten motor bolts (inspect one month after start-up). x

23 Inspect seals (inspect one month after start-up). x

24 Inspect belt. x

Inspect media, rim, spokes and shaft (inspect one month after

start-up).

26 Inspect the general condition of the plate heat exchanger. x

27 Measure pressure drop across the plate heat exchanger. If needed

28 Inspect the burner area for hazardous material. x

29 Inspect the stack. x

30 Inspect condensate drain connections and disposal system. x

31 Clean and recalibrate all controls. x

32 Inspect the gas piping. x

33 Inspect burner motor (or every 500 hours, whatever comes ﬁrst). x

34 Verify all electrical connections, tighten if necessary. x

35 Verify all fuse holders. x

36 Verify all motor overload settings. x

37 Inspect fan blades for cracks. x

38 Inspect for wear and tension. x

Look for oil on all refrigeration components (including coils, com-

pressors, etc.) to indicate a refrigerant leak.

40 Verify for proper superheat. x

Verify each circuit refrigerant site glass when the circuit is operat-

ing under steady state, full load conditions. It should be full and clear. If not, look for refrigerant leaks.

Semi-

annually

Annually

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Page 99

Appendix J: Measuring and Adjusting V-belt Tension

Table J1: Measuring V-belt Tension

V-belt Cross Section

3VX

5VX

Small Sheave Diameter

Range (Inches)

9.0 to 12.0

13.0 to 16.0

12.0 to 15.5

16.0 to 18.0

22.0 to 27.0

17.7 to 23.6

23.7 to 31.5

31.6 to 39.6

9.0 to 12.0

13.0 to 16.0

2.65 to 3.35

3.65 to 4.12

6.0 to 10.6

9.0 to 11.8

12.5 to 16.0

17.0 to 20.0

21.0 to 24.8

2.20 to 3.35

3.65 to 4.12

4.50 to 5.60

6.00 to 10.60

9.0 to 11.8

12.5 to 16.0

3.0 to 3.4

3.6 to 4.2

4.6 to 6.0

4.6 to 5.4

5.6 to 7.4

8.6 to 9.4

7.0 to 8.5

2.1 to 3.4

3.6 to 4.2

4.6 to 6.0

3.7 to 5.4

5.6 to 7.4

8.6 to 9.4

5.8 to 8.5

4.5 to 5.6

7.1 to 8.5

4.4 to 8.5

Initial Installation

3.3

3.5

3.7

6.0

6.3

6.6

13.2

13.9

14.6

26.5

27.8

29.1

39.7

41.7

43.7

4.4

4.6

4.9

7.7

8.2

8.6

17.2

18.1

19.0

5.5

6.4

7.5

8.6

19.2

23.3

27.3

50.9

57.1

61.3

5.5

6.4

7.5

8.6

19.2

23.3

27.3

Recommended Deﬂection Force (lbs)

Retensioned

Maximum Minimum

2.9

3.1

3.3

5.1

5.5

5.7

11.5

12.1

12.6

22.9

24.3

25.6

34.4

36.2

37.9

3.7

4.0

4.2

6.6

7.1

7.5

15.0

15.7

16.5

4.8

5.7

6.6

7.5

16.7

20.3

23.8

44.3

49.8

53.3

4.8

5.7

6.6

7.5

16.7

20.3

23.8

2.2

2.4

2.5

4.0

4.2

4.4

8.8

9.3

9.7

17.6

18.7

19.6

26.5

27.8

29.1

2.9

3.1

3.3

5.1

5.5

5.7

11.5

12.1

12.8

3.9

4.4

5.1

5.7

13.0

15.6

18.5

34.4

38.6

41.4

3.9

4.4

5.0

5.7

13.0

15.6

18.5

Plunger with

deflection force scale (lbs)

Small O-ring Large O-ring

Figure J1: Belt tension adjustment

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

Body with deflection

distance scale (inches)

Belt Span

Deflection

Force

Page 100

Appendix K: Energy Recovery Wheel

Multi-link Drive Belt Instructions

How to Measure, Assemble and Install

How to Measure

Pull belt tight around sheaves to check hand tight length, overlapping the last two tabs with two holes in matching links as shown. Count the number of links and remove one link for every 24 of O/3L, A/4L and B/5L sections, and one link for every 20 of C and D sections. This gives the correct installed belt length and will ensure optimum belt tension when running.

Figure K1: Multi-link drive belt

IMPORTANT

Every tenth link is designated with an arrow (←). For multiple belt drive, ensure that each belt has the same number of links.

Disassembly

1. Hold belt upside down. Bend back as far as possible; hold with one hand. Twist one tab 90° parallel with slot.

2. Pull end of link over tab.

3. Rotate belt end with tab 90°.

4. Pull belt end through two links.

2. Place end tab through two links at once.

3. Flex belt further and insert second tab through end link by twisting tab with thumb.

4. Ensure tab returns to position across belt. Reverse belt so tabs run inside.

IMPORTANT

Turn belt inside out (as shown) to ensure easy assembly and disassembly.

Installation

1. Turn belt with tabs to the inside before installing.

2. Determine direction of drive rotation.

3. Align belt directional arrow (←) with drive rotation.

4. Fit belt in nearest groove of smaller sheave.

5. Roll belt onto larger sheave, turning the drive slowly. Belt may seem very tight; this is okay. Do not jog motor.

6. Check to see all tabs are still in their correct position and are not twisted out of alignment.

7. For multiple belt drives, work belt from groove to groove. On particularly wide drives, it may be easier

IMPORTANT

With drive ratios around 1:1, it may be necessary to add back one link to allow belts to be rolled on. This does not apply if using Alternative Installation Method.

Figure K2: Disassemble multi-link drive belt

Assembly

1. Hold belt with tabs pointing outward.

Figure K3: Assemble multi-link drive belt

to install half the belts from the inboard side and half from the outboard.

Alternative Installation Method

1. Set motor in mid position of adjustment range and mark base clearly.

2. Determine required belt length as described in How to Measure section.

3. Push motor forward to minimum center distance.

4. Install belts as in Installation section.

5. Pull motor back to previously marked mid position.

Retensioning

Like all high performance V-belts, PowerTwist Plus V-belts require the maintenance of correct drive tension to operate efﬁciently. Experience indicates that drive tension should be checked after 24 hours running at full load. A retension may be necessary depending on the severity of the drive. Any initial belt stretch is then taken up. Subsequently, belt tension should be checked periodically and adjusted when necessary.

VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000

100