Greenheck 471849 VersiVent Installation and Operation Manual

Document 471849
Energy Recovery Ventilator
VersiVent
®
Installation, Operation and Maintenance Manual
Please read and save these instructions for future reference. Read carefully before attempting to assemble,
install, operate or maintain the product described. Protect yourself and others by observing all safety
information. Failure to comply with instructions could result in personal injury and/or property damage!
VersiVent - Model VER
General Safety Information
Only qualified personnel should install this system.
Personnel should have a clear understanding of these
instructions and should be aware of general safety
precautions. Improper installation can result in electric
shock, possible injury due to coming in contact with
moving parts, as well as other potential hazards. Other
considerations may be required if high winds or seismic
activity are present. If more information is needed,
contact a licensed professional engineer before moving
forward.
DANGER
Always disconnect power before working on or near
this equipment. Lock and tag the disconnect switch or
breaker to prevent accidental power up.
CAUTION
When servicing the unit, the internal components may
be hot enough to cause pain or injury. Allow time for
cooling before servicing.
1. Follow all local electrical and safety codes, as well as
the National Electrical Code (NEC), the National Fire
Protection Agency (NFPA), where applicable. Follow
the Canadian Electric Code (CEC) in Canada.
2. All moving parts must be free to rotate without
striking or rubbing any stationary objects.
3. Unit must be securely and adequately grounded.
4. Do not spin fan wheel faster than maximum
cataloged fan RPM. Adjustments to fan speed
significantly affects motor load. If the fan RPM is
changed, the motor current should be checked to
make sure it is not exceeding the motor nameplate
amps.
5. Do not allow the power cable to kink or come in
contact with oil, grease, hot surfaces or chemicals.
Replace cord immediately if damaged.
6. Verify that the power source is compatible with the
equipment.
7. Never open access doors to the unit while it is
running.
CAUTION
Precaution should be taken in explosive atmospheres.
VersiVent Energy Recovery Ventilator
1
Table of Contents
General Safety Information . . . . . . . . . . . . . . . . . . .1
Receiving, Handling and Storage . . . . . . . . . . . . . .3
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Optional Subassemblies . . . . . . . . . . . . . . . . . . . . . .4
Installation
Unit Dimensions and Weights . . . . . . . . . . . . . . . . . .5
Curb Outside Dimensions and Weights . . . . . . . . . . .6
Service Clearances . . . . . . . . . . . . . . . . . . . . . . . . . .7
Access Panel Descriptions and Locations . . . . . . . .8
Recommended Roof Openings . . . . . . . . . . . . . . . . .9
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Roof Curb Mounting . . . . . . . . . . . . . . . . . . . . . . . .10
Rail Mounting/Layout . . . . . . . . . . . . . . . . . . . . . . . .10
Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . .11
Electrical Installation
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Field-Provided Disconnect. . . . . . . . . . . . . . . . . . . .13
Discharge Air Temperature Sensor . . . . . . . . . . . . .13
Typical Control Center Components . . . . . . . . . . . .13
Optional Accessory Wiring Schematics. . . . . . . . . .14
Piping Installation
Optional Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . .15
Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Optional Coil Piping . . . . . . . . . . . . . . . . . . . . . . . . .15
Water Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Direct Expansion . . . . . . . . . . . . . . . . . . . . . . . . .15
Condensate Drain Trap . . . . . . . . . . . . . . . . . . . .16
Unit Overview
Basic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Optional Component Overview
Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Frost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Variable Frequency Drive . . . . . . . . . . . . . . . . . . . . .18
CO2 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Phase Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Rotation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Dirty Filter Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .18
Microprocessor Controller . . . . . . . . . . . . . . . . . . . .19
Unoccupied Recirculation Damper . . . . . . . . . . . . .19
Service Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Vapor Tight Lights . . . . . . . . . . . . . . . . . . . . . . . . . .19
Hot Gas Bypass Valve . . . . . . . . . . . . . . . . . . . . . . .19
Hot Gas Reheat Valve . . . . . . . . . . . . . . . . . . . . . . .19
Digital Scroll Compressor . . . . . . . . . . . . . . . . . . . .19
Cooling System Overview
Packaged DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Start-Up
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Special Tools Required . . . . . . . . . . . . . . . . . . . . . .21
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . .21
Voltage Imbalance . . . . . . . . . . . . . . . . . . . . . . . . . .21
Pre-Start-Up Checklist . . . . . . . . . . . . . . . . . . . . . . .22
Start-Up Checklist . . . . . . . . . . . . . . . . . . . . . . . 22-23
Optional Accessories Checklist . . . . . . . . . . . . . . . .24
2
VersiVent Energy Recovery Ventilator
Start-Up Components
Energy Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Fans - Supply and Exhaust . . . . . . . . . . . . . . . . 25-26
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Hot Gas Bypass Valve . . . . . . . . . . . . . . . . . . . . . . .26
Optional Components Start-Up
Dirty Filter Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .27
Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Frost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Variable Frequency Drives . . . . . . . . . . . . . . . . 29-30
Routine Maintenance
Maintenance Frequency. . . . . . . . . . . . . . . . . . . . . .31
Units with Packaged DX . . . . . . . . . . . . . . . . . . . . .31
Maintenance Procedures
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Fan Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Fan Wheel and Fasteners . . . . . . . . . . . . . . . . . .32
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Internal Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
External Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Door Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Energy Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Troubleshooting
Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Refrigeration Circuit . . . . . . . . . . . . . . . . . . . . . . 36-39
Energy Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Controller Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Rotation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Digital Scroll Compressor . . . . . . . . . . . . . . . . . . . .40
Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Reference
Technical Assistance Information . . . . . . . . . . . . . .41
Additional Installation, Operation and
Maintenance Manuals . . . . . . . . . . . . . . . . . . . . .41
Component Location . . . . . . . . . . . . . . . . . . . . . . . .42
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Our Commitment . . . . . . . . . . . . . . . . . . . . Backcover
Receiving
Upon receiving the product check to make sure all items
are accounted for by referencing the bill of lading to
ensure all items were received. Inspect each crate for
shipping damage before accepting delivery. Notify the
carrier if any damage is noticed. The carrier will make
notification on the delivery receipt acknowledging any
damage to the product. All damage should be noted on
all the copies of the bill of lading which is countersigned
by the delivering carrier. A Carrier Inspection Report
should be filled out by the carrier upon arrival and
reported to the Traffic Department. If damaged upon
arrival, file claim with carrier. Any physical damage to
the unit after acceptance is not the responsibility of
manufacturer.
Unpacking
Verify that all required parts and the correct quantity
of each item have been received. If any items are
missing, report shortages to your local representative to
arrange for obtaining missing parts. Sometimes it is not
possible that all items for the unit be shipped together
due to availability of transportation and truck space.
Confirmation of shipment(s) must be limited to only
items on the bill of lading.
Handling
Units are to be rigged and moved by the lifting brackets
provided or by the skid when a forklift is used. Location
of brackets varies by model and size. Handle in such
a manner as to keep from scratching or chipping the
coating. Damaged finish may reduce ability of unit to
resist corrosion.
Storage
Units are protected against damage during shipment. If
the unit cannot be installed and operated immediately,
precautions need to be taken to prevent deterioration of
the unit during storage. The user assumes responsibility
of the unit and accessories while in storage. The
manufacturer will not be responsible for damage during
storage. These suggestions are provided solely as a
convenience to the user.
INDOOR — The ideal environment for the storage of
units and accessories is indoors, above grade, in a
low humidity atmosphere which is sealed to prevent
the entry of blowing dust, rain, or snow. Temperatures
should be evenly maintained between 30°F (-1°C)
and 110°F (43°C) (wide temperature swings may
cause condensation and “sweating” of metal parts).
All accessories must be stored indoors in a clean, dry
atmosphere.
Remove any accumulations of dirt, water, ice, or snow
and wipe dry before moving to indoor storage. To avoid
“sweating” of metal parts allow cold parts to reach room
temperature. To dry parts and packages use a portable
electric heater to get rid of any moisture build up. Leave
coverings loose to permit air circulation and to allow for
periodic inspection.
The unit should be stored at least 3½ in. (89 mm) off the
floor on wooden blocks covered with moisture proof
paper or polyethylene sheathing. Aisles between parts
and along all walls should be provided to permit air
circulation and space for inspection.
OUTDOOR — Units designed for outdoor applications
may be stored outdoors, if absolutely necessary. Roads
or aisles for portable cranes and hauling equipment are
needed.
The fan should be placed on a level surface to prevent
water from leaking into the unit. The unit should be
elevated on an adequate number of wooden blocks so
that it is above water and snow levels, and has enough
blocking to prevent it from settling into soft ground.
Locate parts far enough apart to permit air circulation,
sunlight, and space for periodic inspection. To minimize
water accumulation, place all unit parts on blocking
supports so that rain water will run off.
Do not cover parts with plastic film or tarps as these
cause condensation of moisture from the air passing
through heating and cooling cycles.
Inspection and Maintenance during
Storage
While in storage, inspect fans once per month. Keep a
record of inspection and maintenance performed.
If moisture or dirt accumulations are found on parts,
the source should be located and eliminated. At each
inspection, rotate the fan wheel by hand ten to fifteen
revolutions to distribute lubricant on motor. Every three
months, the fan motor should be energized. If paint
deterioration begins, consideration should be given to
touch-up or repainting. Fans with special coatings may
require special techniques for touch-up or repair.
Machined parts coated with rust preventive should be
restored to good condition promptly if signs of rust
occur. Immediately remove the original rust preventive
coating with petroleum solvent and clean with lint-free
cloths. Polish any remaining rust from surface with
crocus cloth or fine emery paper and oil. Do not destroy
the continuity of the surfaces. Wipe thoroughly clean
with Tectyl® 506 (Ashland Inc.) or the equivalent. For
hard to reach internal surfaces or for occasional use,
consider using Tectyl® 511M Rust Preventive or WD-40®
or the equivalent.
REMOVING FROM STORAGE — As units are removed
from storage to be installed in their final location, they
should be protected and maintained in a similar fashion,
until the equipment goes into operation.
Prior to installing the unit and system components,
inspect the unit assembly to make sure it is in working
order.
1. Check all fasteners, set screws on the fan, wheel,
bearings, drive, motor base, and accessories for
tightness.
2. Rotate the fan wheel(s) by hand and assure no parts
are rubbing.
VersiVent Energy Recovery Ventilator
3
Product Overview
The VER units bring in fresh, outdoor air and remove
stale, exhaust air. Prior to discharging the exhaust air,
the energy recovery wheel transfers energy from the
exhaust air to the outdoor air at an efficiency of 7080%. Simply put, this unit preconditions the outdoor
air to save money on heating and cooling costs. These
particular units also have cooling and heating options
available after the recovery wheel to further condition
the fresh air.
Optional Subassemblies
Dampers
Backdraft dampers are always included as an integral
part of the exhaust hood assemblies. Motorized outdoor
air and return air dampers are optional and are factorymounted (and wired) at the intake.
Hot Water / Chilled Water Coils
Water coils can be used for a single purpose such
as heating or cooling, or their function can be
alternated between heating and cooling by changing
the temperature of the water flowing through the coil.
Depending on the application, it may be necessary to
use a glycol mixture to prevent the liquid from freezing.
The water coils are engineered to operate at pressures
up to 250 PSIG and temperatures up to 300°F, but
ancillary equipment such as valves and pumps will often
dictate lower operating temperatures. All water coils
are pressure tested at the factory with 450 PSIG of dry
nitrogen.
Packaged Direct Expansion (PDX)
The DX system comes fully charged from the factory
with refrigerant and is ready for installation upon arrival.
All units come standard with two compressors. This
allows for staging of compressors to meet a wider range
of outdoor air loads while reducing the amount of cycles
per compressor.
Integral Components
All units are provided with an expansion valve, hermetic
scroll compressor(s), liquid line filter drier, high pressure
manual reset cutout, low pressure auto-reset cutout,
time delays for compressor protection, service/charging
valves, moisture indicating sight glass, and optional hot
gas bypass. The compressors also come standard with
a crankcase heater for additional protection.
Split DX
The unit can be equipped with two evaporator coils
that will be connected to a separate condensing unit
(provided by others). Depending on controlling options,
the condensing unit will be controlled by others or could
receive a call for stage 1 and stage 2 of cooling with the
integral microprocessor controller. The microprocessor
controller will only provide a call for cooling, it will not
send a digital control signal to the compressors. Piping
components such as thermostatic expansion valve, filter
drier, sight glass, etc., shall be field-provided.
4
VersiVent Energy Recovery Ventilator
Electric Post-Heaters
The optional post-heater is used as a heat source for
the building and is integrated into the supply airstream.
A temperature sensor (with a field-adjustable set point)
is mounted in the supply airstream after the post-heater
to turn the post-heater on. A SCR heater allows for
an infinite amount of modulating control of the heat to
provide an accurate discharge temperature during the
call for heat.
As standard, the post-heater control panel is not single
point wired to the unit control center. Separate power
must be supplied to the post-heater disconnect (located
in unit control center). Electric heaters are available in
208, 230, 460, or 575 VAC (refer to heater nameplate for
voltage).
Indirect Gas Furnace
An optional indirect gas furnace may be installed and
provides supplementary heat to the building. Refer to
the PVF/PVG Indirect Gas-Fired Heat manuals provided
with the unit. A unit-specific wiring diagram is located
inside the furnace housing access door.
Outdoor Air Weatherhood
Outdoor air weatherhood will be factory-mounted.
Exhaust Air Weatherhood
The exhaust weatherhood is shipped separately as a
kit with its own instructions. Backdraft dampers are
always included as an integral part of the exhaust hood
assemblies.
Installation
Unit Weights & Dimensions
L*
B
A
C
D*
E
F
G
I
Exhaust Air
Discharge
Condensing Coil
4-inch Final Filters
2-inch Filters
Wheel Cassette
2-inch Filters
W
Outdoor Air Intake
Electrical Box
Supply Air
Discharge
Return Air
Intake
Plan View
Optional
Coil Section
Blower
Section
Optional
Condensing Section
Optional
IG Heater Section
oil
gC
sin
en
nd
Co
2-inch Filters
4-inch Final Filters
2-inch Filters
Wheel
Section
Wheel Cassette
H
Outdoor Air Hood
Intake
Section
Drain Pan Connection
IG Gas Connection
Elevation View
Unit
Size
A
B
C
VER-45
16.381
28.146
VER-65
16.381
30.825
VER-90
16.381
34.825
D*
E
F
G
H
I
W
50.275
36.312
47.571
63.964
65.851
18.780
69.987
50.275
38.124
47.571
65.958
72.098
23.358
76.246
50.275
41.312
47.571
65.958
65.851
23.358
91.010
D1
D2
D3
D4
44.627
30.159
36.159
44.159
46.597
30.159
36.159
44.159
85.658
30.159
36.159
44.159
L*
^Weight
(lbs.)
see
note
6300
4900
7250
All dimensions shown in inches.
*L
Sum the lengths of the appropriate modules to get the total length of the unit.
^Weight: The weights shown are a worse case scenario based on the sheet metal and component weights for the unit. These weights include sheet metal
weights added together with the largest fans, coils and heaters for the unit.
D* Coil Module Options
D1
D2
D3
D4
HW
HW + DX
CW + HP
HW + CW + HP
CW
HW + CW
DX + HP
HW + DX + HP
DX
EH + CW
DX + HGRH
EH + DX + HP
EH
EH + DX
DX + HW + HGRH
EH + CW + HP
DX + EH + HGRH
HW = Hot Water
CW = Chilled Water
DX = Direct Expansion
EH = Electric Heat
HP = Wrap-around Heat Pipe
HGRH = Hot Gas Reheat
VersiVent Energy Recovery Ventilator
5
Curb Outside Dimensions and Weights
Blower
Section
Optional
Condensing Section
Optional
IG Heater Section
2-inch Filters
Co
il
ns
ing
Co
nd
e
2-inch Filters
Wheel Cassette
Optional
Coil Section
4-inch Final Filters
Wheel
Section
Outdoor Air Weatherhood
Intake
Section
L* - 3.75 inches
W - 3.75 inches
A
B
C*
D
E
Drain Pan Connection
F
Subtract 3.75 inches from dimensions
W & L* to get the outside curb dimensions.
IG Gas Connection
L*
Elevation View
Unit
Size
A
B
VER-45
28.146
44.627
C*
C1
C2
C3
C4
30.159
36.159
44.159
50.275
D
E
F
W
36.312
47.571
27.909
69.987
VER-65
30.825
46.597
30.159
36.159
44.159
50.275
38.124
47.571
27.909
76.246
VER-90
34.825
85.658
30.159
36.159
44.159
50.275
41.312
47.571
27.909
91.010
L*
Curb Weight^
(lbs.)
447
see
note
473
621
All dimensions shown in inches.
L* — Sum up the applicable section dimensions (A–F) for your unit to get the overall length.
^ — Curb weights shown are for the worst case scenario (largest curb) possible for each size unit.
C* Coil Module Options
C1
C2
C3
C4
HW
HW + DX
CW + HP
HW + CW + HP
CW
HW + CW
DX + HP
HW + DX + HP
DX
EH + CW
DX + HGRH
EH + DX + HP
EH
EH + DX
DX + HW + HGRH
EH + CW + HP
DX + EH + HGRH
HW = Hot Water
EH = Electric Heat
CW = Chilled Water
HP = Wrap-around Heat Pipe
DX = Direct Expansion
HGRH = Hot Gas Reheat
2½ in.
1.195 in.
1in.
1in.
Roof Curb
Recommended
2-inches of
Insulation
Curb Cap Details
6
Control wires should not be run inside the same conduit
as that carrying the supply power. Make sure that fieldsupplied conduit does not interfere with access panel
operation.
If wire resistance exceeds 0.75 ohms, an industrial-style
plug-in relay should be added to the unit control center
and wired in lieu of the remote switch (typically between
terminal blocks R and G on the terminal strip (refer to
Typical Control Center Components). The relay must be
rated for at least 5 amps and have a 24 VAC coil. Failure
to comply with these guidelines may cause motor
starters to “chatter” or not pull in which can cause
contactor failures and/or motor failures.
Side of Unit
1in.
Most factory-supplied electrical components are prewired. To determine what electrical accessories require
additional field wiring, refer to the unit-specific wiring
diagram located on the inside of the unit control center
access door. The low voltage control circuit is 24 VAC
and control wiring should not exceed 0.75 ohms.
VersiVent Energy Recovery Ventilator
Note: Standard factory-installed electric post-heaters
have their own disconnect separate from the
unit disconnect. Thus, each electric post-heater
requires its own separate power connection.
Service Clearances
B
ACCESS
PANEL
ACCESS
PANEL
ACCESS
PANEL
TL
TR
VER-45, 65 and 90 units require minimum clearances
for access on all sides for routine maintenance. Filter
replacement, drain pan inspection and cleaning, energy
wheel cassette inspection, fan bearing lubrication and
belt adjustment are examples of routine maintenance
that must be performed. Blower and motor assemblies,
energy recovery wheel cassette, coil and filter sections
are always provided with a service door or panel for
proper component access. Clearances for component
removal may be greater than the service clearances,
refer to drawings for these dimensions.
Additional clearances for units with packaged DX
A
C
ACCESS
PANEL
VER-90
ONLY
ACCESS
PANEL
TL
TR
Clearances must be maintained on all sides of this unit.
This especially is true with the top of this unit. Hot air is
being discharged through the condensing fans during
operation, and the more clearance available, the better
the chance of avoiding recirculation or coil starvation.
This unit should never be placed under an overhang
or inside a building. A minimum of 48 inches over the
condensing fans is recommended.
Minimum 48 inches
clearance
Minimum 24 inches
clearance
TL
ACCESS
PANEL
TR
TL
Condensing Coil Intake
ACCESS
PANEL
TR
Keep this area clear
ACCESS
PANEL
Unit Clearances
A
B
C
D
VER-45
65
42
36
24
VER-65
70
42
36
24
VER-90
65
42
65
24
TL
Unit Size
TR
All dimensions shown in inches.
ACCESS
PANEL
ACCESS
PANEL
TR
D
Access Panels may change depending on options
selected.
VersiVent Energy Recovery Ventilator
7
Access Panel Descriptions and Locations
Following is a list of items accessible through the
access doors shown on the diagrams. Some items are
optional and may not have been provided.
#2 – OA Intake Damper
and Electric Preheat
#6 – Control Panel
1
2
#8 – Supply Fan
#9 – Compressors
3
8
4
5
6
7
9
#3 – Exhaust Fan
9
#4 – Filter & Wheel
#7 – IG Furnace
Control Center
#5 – Packaged DX
Coil and Final Filter
1. Aluminum mesh filters (intake hood)
2. Outdoor air intake damper
Electric pre-heater
3. Exhaust fan, motor, and drives
4. Energy recovery wheel, motor, belt, and seals
Exhaust air filters
Return air intake damper (optional)
Outdoor air filters
Frost control sensors (optional)
Economizer sensors (optional)
5. Coil access / drain pan / final filters
Bypass damper (optional)
8
VersiVent Energy Recovery Ventilator
6. Control center
All electrical controls
VFD for energy recovery wheel (optional)
7. Indirect gas furnace control center
8. Supply air fan, motor, and drives
(with indirect gas furnace)
Electric post-heater control center (optional)
9. Compressor(s) – (optional)
Handling
Refer to weight and dimension data to determine the
exact location of the section containing the outdoor
air discharge opening. If the unit is equipped with
an Indirect Gas Heater (IG) section, the outdoor air
discharge opening will be in that section; if not, it will
be in the blower section. The return air intake will
be consistent for all units. The dimensions of these
openings and their locations are illustrated below.
While this unit was constructed with quality and
dependability in mind, damage still may occur during
handling of the unit for installation. Exercise extreme
caution to prevent any damage from occurring to the
refrigerant system. This unit could contain a system
pressurized with refrigerant that, if damaged, could
leak into the atmosphere or cause bodily harm due to
the extreme cold nature of expanding refrigerant. Use
protective equipment such as gloves and safety glasses
to minimize or prevent injury in case of a system leak
during installation.
Return Air Intake
Recommended Roof Opening
A
Supply Air
Discharge
F
H
B
C
VER-45
1
2
3
4
VER-65
1
2
3
4
VER-90
1
2
3
4
D
A
56.9
56.9
56.9
56.9
A
59.9
59.9
59.9
59.9
A
77.9
77.9
77.9
77.9
E
B
4.7
4.7
4.7
4.7
B
6.3
6.3
6.3
6.3
B
4.7
4.7
4.7
4.7
C
51.5
51.5
51.5
51.5
C
56.1
56.1
56.1
56.1
C
99.2
99.2
99.2
99.2
D
15.9
15.9
15.9
15.9
D
15.9
15.9
15.9
15.9
D
15.9
15.9
15.9
15.9
E
26.9
33.8
33.8
26.9
E
29.9
30.9
30.9
29.9
E
33.8
33.8
33.8
33.8
F
42.7
34.1
34.1
42.7
F
51.9
49.9
49.9
51.9
F
61.9
51.9
51.9
61.9
G
G
3.3
7.4
35.3
31.2
G
2.7
7.3
35.2
30.6
G
2.0
7.5
35.3
29.9
H
11.8
14.4
14.4
11.8
H
10.3
7.1
7.1
10.3
H
12.7
17.7
17.7
12.7
All dimensions are in inches.
IG = Indirect Gas Furnace; PDX = Packaged DX Cooling
1 = Any unit without IG and PDX.
Blower Module is at the end of the unit.
2 = Any unit with IG that does not have PDX.
3 = Any unit with IG and PDX
4 = Any unit without IG and with PDX
The system design and installation should follow
accepted industry practice, such as described in
the ASHRAE Handbook. Adequate space should be
left around the unit for piping coils and drains, filter
replacement, and maintenance. Sufficient space should
be provided on the side of the unit for routine service
and component removal should that become necessary.
Lifting
1. Before lifting, be sure that all shipping material has
been removed from unit.
2. To assist in determining rigging requirements,
weights are provided in the Unit Weights &
Dimensions section.
3. Unit must be lifted by all lifting lugs provided on
base structure.
4. Rigger to use suitable mating hardware to attach to
unit lifting lugs.
5. Spreader bar(s) must span the unit to prevent
damage to the cabinet by the lift cables.
When cutting only duct openings, cut opening one inch
(25 mm) larger than duct size to allow clearance for
installation. Area enclosed by roof curb must comply
with clearance to combustible materials. If the roof is
constructed of combustible materials, area within the
roof curb must be ventilated, left open, or covered with
non-combustible material which has an “R” value of at
least five. If area within curb is open, higher radiated
sound levels may result.
Where the supply or warm air duct passes thru a
combustible roof, a clearance of one inch must be
maintained between the outside edges of the duct
and combustible material in accordance with NFPA
Standard 90A. Position the unit roof opening such that
the supply discharge and exhaust inlet of the unit will
line up with the corresponding ductwork. Be sure to
allow for the recommended service clearances when
positioning opening (see Service Clearances). Do not
face the outdoor air intake of the unit into prevailing
wind and keep the intake away from any other exhaust
fans. Likewise, position the exhaust discharge opening
away from outdoor air intakes of any other equipment.
6. Always test-lift the unit to check for proper balance
and rigging before hoisting to desired location.
7. Never lift units by weatherhoods.
8. Never lift units in windy conditions.
9. Preparation of curb and roof openings should be
completed prior to lifting unit to the roof.
10. Check to be sure that gasketing (supplied by
others) has been applied to the curb prior to lifting
the unit and setting on curb.
11. Do not use fork lifts for handling unit.
VersiVent Energy Recovery Ventilator
9
Roof Curb Mounting
Rail Mounting and Layout
Roof curb details, including duct location dimensions,
are available on VER roof curb assembly instructions.
• Rails designed to handle the weight of the VER
should be positioned as shown on the diagram (rails
by others).
• Make sure that rail positioning does not interfere with
the supply air discharge opening or the return air
intake opening on the VER unit.
• Rails should run the width of the unit and extend
beyond the unit a minimum of 12 inches on each
side.
• Set unit on rails.
Rooftop units require curbs to be mounted first. The
duct connections must be located so they will be clear
of structural members of the building.
1. Factory-Supplied Roof Curbs
Roof curbs are Model GKD, which are shipped in a
knockdown kit (includes duct adapter) and require
field-assembly (by others). Assembly instructions are
included with the curb.
2. Install Curb
Locate curb over roof opening and fasten in place.
Check that the diagonal dimensions are within
±1/8 inch of each other and adjust as necessary.
For proper coil drainage and unit operation, it is
important that the installation be level. Shim as
required to level.
3. Install Ductwork
Installation of all ducts should be done in
accordance with SMACNA and AMCA guidelines.
Duct adapter provided to support ducts prior to
setting the unit.
4. Set the Unit
Lift unit to a point directly above the curb and duct
openings. Guide unit while lowering to align with duct
openings. Roof curbs fit inside the unit base. Make
sure the unit is properly seated on the curb and is
level.
Rails are positioned in random places.
See table for proper location
Isometric View
A
Return Air
Intake
Supply Air
Discharge
B
C
D
Side View
Unit
A
B
C
D
VER-45
53.3
16
33.8 w/IG
27 w/o IG
9.2 IG w/o CS; 37.1 IG w/CS
5.2 w/o IG and CS
33.1 w/o IG and w/ CS
VER-65
58.1
16
31.0 w/IG
30 w/o IG
9 IG w/o CS; 36.9 IG w/CS
4.6 w/o IG and CS
32.5 w/o IG and w/ CS
VER-90
105.3
16
33.8 w/IG
34 w/o IG
9.2 IG w/o CS; 37.1 IG w/CS
3.7 w/o IG and CS
31.6 w/o IG and w/ CS
All dimensions shown in inches.
IG = Indirect Gas
CS = Condensing Section
10 VersiVent Energy Recovery Ventilator
Ductwork Connections
Supply Fan
The supply fan in this unit is a plenum style fan. The
discharge opening dimensions are provided. For proper
fan performance, match the duct size to the dimensions
listed. Installation of all ducts should be done in
accordance with SMACNA.
Supply Fan Discharge Opening Dimensions
Supply Air
Discharge Location
Top
End
Bottom
Length of
Straight Duct
(Supply Fan)
VER-45
38.5 x 30
41.8 x 27
*
48
VER-65
50 x 31
50 x 31
*
60
VER-90
62 x 34
59.7 x 35
*
60
Unit
All dimensions shown in inches.
* See diagram in Recommended Roof Openings section for the
Bottom Discharge opening sizes.
Ro
Exhaust Fan
The exhaust fan in this unit is a forward-curved fan.
Good and poor fan-to-duct connections are shown.
Airflow out of the fan should be
directed straight or curved the
same direction as the
fan wheel rotates. Poor
ion
tat
duct installation will
result in low airflow and
other system effects.
Ro
POOR
ion
tat
Length of Straight Duct
GOOD
Recommended Exhaust Fan Discharge Duct Size
Unit
Duct Size
Exhaust
Blower Size
Length of
Straight Duct
(Exhaust Fan)
VER-45
20 x 20
12
48
VER-65
28 x 28
15
60
VER-90
32 x 32
18
60
All dimensions shown in inches.
• Recommended duct sizes are based on velocities across the
cfm range of each model at approximately 800 feet per minute
(FPM) at minimum airflow and up to 1600 fpm at maximum
airflow. Recommended duct sizes are only intended to be a
guide and may not satisfy the requirements of the project. Refer
to plans for appropriate job specific duct size and/or velocity
limitations.
• Straight duct lengths were calculated based on 100% effective
duct length requirements as prescribed in AMCA Publication
201. Calculated values have been rounded up to nearest foot.
VersiVent Energy Recovery Ventilator 11
Electrical Installation
WARNING
The roof lining contains high voltage wiring. To prevent
electrocution, do not puncture the interior or exterior
panels of the roof.
WARNING
To prevent injury or death due to electrocution or
contact with moving parts, lock disconnect switch
open.
For units with a gas furnace, if you turn off the power
supply, turn off the gas.
IMPORTANT
Before connecting power to the unit, read and
understand the following instructions and wiring
diagrams. Complete wiring diagrams are attached on
the inside of the control center door(s).
IMPORTANT
All wiring should be done in accordance with the latest
edition of the National Electrical Code ANSI/NFPA 70
and any local codes that may apply. In Canada, wiring
should be done in accordance with the Canadian
Electrical Code.
IMPORTANT
The equipment must be properly grounded and
bonded. Any wiring running through the unit in the
airstream must be protected by metal conduit, metal
clad cable or raceways.
CAUTION
If replacement wire is required, it must have a
temperature rating of at least 105°C, except for an
energy cut-off or sensor lead wire which must be rated
to 150°C.
DANGER
High voltage electrical input is needed for this
equipment. This work should be performed by a
qualified electrician.
CAUTION
Any wiring deviations may result in personal injury or
property damage. Manufacturer is not responsible
for any damage to, or failure of the unit caused by
incorrect final wiring.
WARNING
If unit is equipped with a microprocessor, terminals Y1,
Y2 and W1 cannot be wired to a thermostat. Wiring to
these terminals will bypass unit’s internal safeties.
12 VersiVent Energy Recovery Ventilator
1. Determine the Size of the Main Power Lines
The unit’s nameplate states the voltage and the unit’s
MCA. The main power lines to the unit should be
sized accordingly. The nameplate is located on the
outside of the unit on the control panel side.
2. Determine the Size of Electric Heater Wiring
An optional electric heater may require a separate
power supply. The power connection should
be made to the factory-provided electric heater
disconnect and must be compatible with the ratings
on the nameplate, supply power voltage, phase and
amperage. Consult ANSI/NFPA 70 and CSA C22.1
for proper conductor sizing.
3. Provide the Opening(s) for the Electrical
Connections
Electrical openings vary by unit size and arrangement
and are field-supplied.
4. Connect the Power Supplies
Connect the main power lines and electric heater
power lines to the disconnect switches or terminal
blocks and main grounding lug(s). Torque field
connections to manufacturer’s recommendations.
5. Wire the Optional Convenience Outlet
The convenience outlet requires a separate 115V
power supply circuit. The circuit must include short
circuit protection which may need to be supplied by
others.
6. Connect Field-Wired Low Voltage Components
Most factory-supplied electrical components are
prewired. To determine what electrical accessories
require additional field-wiring, refer to the unitspecific wiring diagram located on the inside of the
control center access door.
If unit is equipped with a microprocessor, terminals Y1,
Y2 and W1 cannot be wired to a thermostat. Wiring to
these terminals will bypass unit’s internal safeties.
Control wires should not be run inside the same conduit
as that carrying the supply power. Make sure that
field-supplied conduit does not interfere with access
panel operation. All low voltage wiring should be run in
conduit wherever it may be exposed to the weather.
The low voltage control circuit is 24 VAC and control
wiring should not exceed 0.75 ohms. If wire resistance
exceeds 0.75 ohms, an isolation relay should be added
to the unit control center and wired in place of the
remote switch (typically between terminal blocks R
and G on the terminal strip). The relay must be rated
for at least 5 amps and have a 24 VAC coil. Failure to
comply with these guidelines may cause motor starters
to “chatter” or not pull in which can cause contactor
failures and/or motor failures.
Field-Provided Disconnect
Typical Control Center Components
If field-installing an additional disconnect switch, it
is recommended that there is at least four feet of
service room between the switch and system access
panels. When providing or replacing fuses in a fusible
disconnect, use dual element time delay fuses and size
according to the rating plate.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Discharge Air Temperature Sensor
Without Indirect Gas Furnace
For units without an indirect gas furnace, the discharge
air temperature sensor is factory-mounted in the blower
discharge section of the unit behind the blower cut off
plate.
WARNING
Discharge air temperature sensor is to be fieldinstalled prior to unit start-up on units with an indirect
gas furnace.
With Indirect Gas Furnace
For units with an indirect gas furnace, the discharge
air temperature sensor is to be
field-installed prior to unit start
up at least three duct diameters
downstream of the heat exchanger
or where good mixed average
temperature occurs in the ductwork.
The discharge air sensor is shipped
loose and can be found in the unit’s
control center. See the unit-specific
wiring diagram for connection locations.
Main Disconnect (non-fusible, lockable)
Motor Starter - Exhaust Air Fan
Motor Starter - Supply Air Fan
Motor Contactor - Energy Wheel
24 VAC Control Transformer
24 VAC Terminal strip
Fuses for blower motors*
Grounding lug
Distributor block*
Compressor fuse blocks*
Compressor contactors*
Condensing fan contactors*
Compressor relay*
Terminal block*
Compressor cycle timers*
Optional Control Center Components
16. DDC controller*
17. Dirty filter pressure switches*
18. Terminal block
19. Energy recovery wheel VFD*
*Not always provided
8
1
5
18
6
7
9
13
2
3
4
19
15
17
10
16
11
12
14
VersiVent Energy Recovery Ventilator 13
Optional Accessory Wiring Schematics
Remote Panel
The remote panel is available with a number of different
alarm lights and switches to control the unit. The remote
panel ships loose and requires mounting and wiring in
the field. The remote panel is available with the following
options:
Unit on/off switch
Unit on/off light
7-day time clock
On/off/auto switch
Dirty filter light
Economizer light
Frost control light
Wheel rotation sensor light
Heating/Cooling Switches and Night Setback Switch/
Timer
TERMINAL BLOCKS IN
UNIT CONTROL CENTER
R
C
S1
S6
S7
S4
UNIT ON/OFF
G
COOL STAGE 1 / ECONOMIZER
Y1
COOL STAGE 2
Y2
HEAT
W1
6
7
12
7-Day Timer
S5
UNOCCUPIED RECIRCULATION
A
•
•
•
•
•
•
•
•
Unit Interfacing Terminals
TERMINAL BLOCKS IN
UNIT CONTROL CENTER
R
BLACK
C
BLUE
Dirty Filter Indicator
G
(Powered by others)
Y1
TIMER
RED
HOT
Y2
COMMON
(CAPPED)
W1
6
7
12
On/Off/Auto Switch & Indictor Light Wiring
SUPPLY DIRTY
FILTER SWITCH
NC
C
NO
NC
C
NO
TERMINAL BLOCKS IN
UNIT CONTROL CENTER
R
EXHAUST DIRTY
FILTER SWITCH
C
ON
UNIT ON/OFF
G
OFF
AUTO
*
Y1
Y2
* -- BMS, TIMECLOCK,
TSTAT, RTU, ETC.
W1
6
FROST CONTROL
7
ECONOMIZER
12
SUPPLY DIRTY
FILTER SWITCH
EXHAUST DIRTY
FILTER SWITCH
WHEEL ROTATION
NC
C
NO
NC
C
NO
DIRTY FILTER
ON/OFF/AUTO SWITCH ALLOWS THREE MODES OF OPERATION
"ON" - UNIT IS TURNED ON MANUALLY
"OFF" - UNIT IS TURNED OFF MANUALLY
"AUTO" - UNIT IS CONTROLLED VIA SCHEDULER OF BMS, TIMECLOCK, TSAT, ETC.
14 VersiVent Energy Recovery Ventilator
DIRTY FILTER
Piping Installation
Water Coils
Optional Gas Piping
Units with indirect gas-fired furnaces require fieldsupplied and installed gas supply piping. The unit gas
connection is 3⁄4 inch NPT. The maximum allowable gas
pressure is 14 in. wg.
Ground
Joint
Union
Gas to
Controls
Gas Cock
From Gas Supply
Bleeder Valve or
1/8 in Plugged Tap
8 in. Trap
Typical Gas Supply Piping Connection
Gas Connections
If this unit is equipped with an indirect gas-fired furnace,
connection to an appropriate gas supply line will be
required. For complete information on installation
procedures for the optional gas furnace, refer the
PVF/PVG Indirect Gas-Fired Heat Module Installation,
Operation, and Maintenance Manual.
Optional Coil Piping
Factory-installed cooling and heating components are
mounted in the coil section of the unit. The coil section
is downstream of the energy wheel on the supply air
side of the unit. Note the coil connection locations. Coil
connections are located external to the unit as shown.
DX coil liquid
connection
access door
Water coil
connections
Note: DX coil liquid connection is internal to units.
1. Piping should be in accordance with accepted
industry standards. Pipework should be supported
independently of the coils. When installing couplings,
do not apply undue stress to the connection
extending through the unit. Use a backup pipe
wrench to avoid breaking the weld between coil
connection and header.
2. Connect the water supply to the bottom connection
on the air leaving side and the water return to the
top connection on the air entering side. Connecting
the supply and/or return in any other manner will
result in very poor performance. Be sure to replace
factory-installed grommets around coil connections
if removed for piping. Failure to replace grommets
will result in water leakage into the unit and altered
performance.
3. Water coils are not normally recommended for
use with entering air temperatures below 40°F. No
control system can be depended on to be 100% safe
against freeze-up with water coils. Glycol solutions
or brines are the only safe media for operation of
water coils with low entering air conditions. If glycol
or brine solutions are not used, coils must be drained
when freezing conditions are expected. If required,
vent and drain connections must be fieldpiped, external to the unit.
4. Pipe sizes for the system must be selected on
the basis of the head (pressure) available from the
circulation pump. The velocity should not exceed
6 feet per second and the friction loss should be
approximately 3 feet of water column per 100 feet
of pipe.
5. For chilled water coils, the condensate drain
pipe should be sized adequately to ensure the
condensate drains properly.
Direct Expansion (DX) Coils (Split DX)
1. Piping should be in accordance with accepted
industry standards. Pipework should be supported
independently of the coils. Undue stress should not
be applied at the connection to coil headers.
2. The condensate drain pipe should be sized
adequately to ensure the condensate drains properly.
Refer to Condensate Drain Trap section.
3. When connecting suction and liquid connections
make sure the coil is free from all foreign material.
Make sure all joints are tight and free of leakage. Be
sure to replace factory-installed grommets around
coil connections if removed for piping.
4. Manufacturer does not supply compressor or
condensing units with standard models. For further
instruction on DX coil installation and operation
contact your compressor and/or condenser
manufacturer.
VersiVent Energy Recovery Ventilator 15
Condensate Drain Trap
This unit is equipped with a stainless steel condensate
pan with a 1-inch MPT stainless steel drain connection.
It is important that the drain connection be fitted with a
P trap to ensure proper drainage of condensate while
maintaining internal static pressures.
A P trap assembly (kit) is
supplied with each unit and is
to be assembled and installed
as local conditions require and
according to the assembly
instructions provided with
the P trap. If local and area
codes permit, the condensate
may be drained back onto the
roof, but a drip pad should be
provided beneath the outlet. If local and area codes
require a permanent drain line, it should be fabricated
and installed in accordance with Best Practices and all
codes.
In some climates, it will be necessary to provide freeze
protection for the P trap and drain line. The P trap
should be kept filled with water or glycol solution at
all times and it should be protected from freezing to
protect the P trap from damage. If severe weather
conditions occur, it may be necessary to fabricate a P
trap and drain line of metal and install a heat tape to
prevent freezing.
16 VersiVent Energy Recovery Ventilator
Unit Overview
Optional Component Overview
Basic Unit
Economizer
The unit is pre-wired such that when a call for outside
air is made (via field-supplied 24 VAC control signal
wired to unit control center), the supply fan, exhaust fan,
and energy wheel are energized and optional motorized
dampers open.
The energy wheel operation can be altered to take
advantage of economizer operation (free cooling).
Two modes are available:
1. Stopping the wheel
2. Modulating the wheel
The unit can be supplied with or without heating and
cooling coils. For units with coils, controls can be
supplied by manufacturer or by the controls contractor.
If supplied by the controls contractor, they would
provide, mount, and wire any temperature controllers
and temperature or relative humidity sensors required
for the unit to discharge air at the desired conditions.
However, temperature, pressure, and current sensors
can be provided by manufacturer for purposes of
monitoring via the Building Management System (BMS).
Stopping the wheel: A field-supplied call for cool (Y1)
is required. De-energizing the wheel is accomplished in
one of three ways:
1. The outdoor air temperature is less than the
outdoor dry bulb set point (DRYBLB SET)
2. The outdoor air temperature is less than the return
air temperature
3. The outdoor air enthalpy is within the preset
enthalpy curve
A low temperature lock out (LOW T LOCK) is also set
to deactivate mechanical cooling when it exceeds
the outdoor air temperature (factory default 32°F).
Effectively, the two sensors create a deadband where
the energy recovery wheel will not operate and free
cooling from outside can be brought into the building
unconditioned.
Summer Operation
Outdoor air is preconditioned (temperature and moisture
levels are decreased) by the transfer of energy from the
cooler, drier exhaust air via the energy recovery wheel.
Units supplied with cooling coils can further cool the
air coming off the wheel and strip out moisture to levels
at or below room design. A heating coil downstream of
the cooling coil can reheat the air to a more comfortable
discharge temperature to the space.
Return Air
75°F
50% RH
Exhaust Air
Outdoor Air
95°F
117 grains/lb.
Supply Air
79°F
75 grains/lb.
Winter Operation
Outdoor air is preconditioned (temperature and moisture
levels are increased) by the transfer of energy from the
warmer, more humid exhaust air via the energy recovery
wheel. Units supplied with heating coils can further heat
the air coming off the wheel to levels at or above room
design.
Modulating the wheel (factory): A variable frequency
drive is fully programmed at the factory. A “call for cool”
must be field-wired to the unit (Terminals provided in
unit. Refer to wiring diagram in unit control center.)
to allow for initiation of economizer mode. The unit
recognizes economizer conditions based on one of the
previously mention sensors and set points. The unit will
then modulate the wheel speed to maintain the mixed
air temperature set point (MAT SET).
Modulating the wheel (by others): A variable
frequency drive is fully programmed at the factory.
A field-supplied 0-10 VDC signal will be required for
operation of the energy wheel. The field will be required
to have full control of the energy wheel speed at all
times. If no 0-10 VDC signal is provided, the energy
wheel will run at the factory default of 3 Hz and no
energy transfer will be captured.
Return Air
72°F
40% RH
Exhaust Air
Outdoor Air
10°F
5 grains/lb.
Supply Air
60°F
39 grains/lb.
VersiVent Energy Recovery Ventilator 17
Frost Control
Variable Frequency Drives (VFD)
Extremely cold outdoor air temperatures can cause
moisture condensation and frosting on the energy
recovery wheel. Frost control is an optional feature that
will prevent/control wheel frosting. Three options are
available:
1. Timed exhaust frost control
2. Electric preheat frost control
3. Modulating wheel frost control
Variable frequency drives are used to control the speed
of the fan as either multi-speed or modulating control.
Multi-speed VFDs reference a contact which can be
made by a switch or a sensor with a satisfied set point.
Modulating control references a 2-10 VDC signal to the
VFD which will vary the fan speed from a minimum 50%
to full 100% rpm. An optional CO2 sensor is available to
provide both a set point contact or a modulating 2-10
VDC signal.
All of these options are provided with a thermodisc
mounted in the outdoor air intake compartment and a
pressure sensor to monitor pressure drop across the
energy wheel.
An outdoor air temperature of below 5°F and an
increase in pressure drop would indicate that frost is
occurring. Both the pressure sensor and the outdoor air
thermodisc must trigger in order to initiate frost control.
The two sensors together ensure that frost control is
only initiated during a real frost condition.
Timed exhaust frost control includes a timer in
addition to the thermodisc and wheel pressure sensor.
When timed exhaust frost control is initiated, the timer
will turn the supply blower off. Time exhaust using
default timer setting will shut down the supply fan for
5 minutes every 30 minutes to allow exhaust to defrost
energy wheel. Use the test procedure in the Optional
Components Start-Up section for troubleshooting.
Electric preheat frost control includes an electric
heater (at outdoor air intake) in addition to the
thermodisc and pressure sensor on wheel. When
electric preheat frost control is initiated, the electric
preheater will turn on and warm the air entering the
energy wheel to avoid frosting. Use the test procedure
in the Optional Components Start-Up section for
troubleshooting.
Modulating wheel frost control includes a variable
frequency drive (VFD) in addition to the thermodisc and
pressure sensor. When modulating wheel frost control
is initiated, the VFD will reduce the speed of the wheel.
Reducing the speed of the energy wheel reduces its
effectiveness, which keeps the exhaust air condition
from reaching saturation, thus, eliminating condensation
and frosting. If the outdoor air temperature is greater
than the frost threshold temperature OR the pressure
differential is less than the set point, the wheel will run
at full speed. If the outdoor air temperature is less than
5°F AND the pressure differential is greater than the
set point, the wheel will run at reduced speed until the
pressure differential falls below the set point. The VFD
will be fully programmed at the factory.
18 VersiVent Energy Recovery Ventilator
CO2 Sensor
This accessory is often used in Demand Control
Ventilation (DCV) applications. The factory-provided
sensors can either be set to reference a set point
for multi-speed operation, or output a 2-10 VDC
signal to modulate the fan speed. These can either
be shipped loose to mount in the ductwork, or can
be factory-mounted in the return air intake. Follow
instructions supplied with sensor for installation and
wiring details.
Phase Monitor
The unit control circuitry includes a phase monitor that
constantly checks for phase reversal or loss of phase.
When a fault is detected, it cuts off the 24 VAC that
goes to the low voltage terminal strip, thereby shutting
down the unit.
Rotation Sensor
The rotation sensor monitors energy wheel rotation. If
the wheel should stop rotating, the sensor will close a
set of contacts in the unit control center. Field-wiring of
a light (or other alarm) between terminals R and 12 in
the unit control center will notify maintenance personnel
when a failure has occurred.
Dirty Filter Sensor
Dirty filter sensors monitor pressure drop across the
outdoor air filters, exhaust air filters, or both. If the
pressure drop across the filters exceeds the set point,
the sensor will close a set of contacts in the unit control
center. Field-wiring of a light (or other alarm) to these
contacts will notify maintenance personnel when
filters need to be replaced. The switch has not been
set at the factory due to external system losses that
will affect the switch. This switch will need minor field
adjustments after the unit has been installed with all
ductwork complete. The dirty filter switch is mounted in
the exhaust inlet compartment next to the unit control
center or in unit control center.
Microprocessor Controller
Hot Gas Reheat Valve
The microprocessor controller is specifically designed
and programmed to optimize the performance of the
unit with supplemental
heating and cooling. This
option ensures that the
outdoor air is conditioned
to the desired discharge
conditions. The controller and accompanying sensors
are factory-mounted, wired and programmed. Default
settings are pre-programmed, but are easily fieldadjustable.
Units equipped with a reheat coil
use a three-way valve with actuator
to control the supply air discharge
temperature of the unit during
dehumidification mode. The unit
controller provides a 0-10 VDC
signal to control the amount
of reheat to meet the supply
temperature set point.
The microprocessor controller can be interfaced with
a Building Management System through LonWorks®,
BACnet®, or ModBus.
Please refer to the microprocessor controller for energy
recovery Installation, Operation and Maintenance
manual for detailed information.
Unoccupied Recirculation Damper
The unoccupied recirculation option provides a
recirculation damper from the return air intake to the
supply airstream to reduce heating and cooling loads
when less ventilation is required. During the unoccupied
mode, the exhaust fan will remain off and the supply
air fan will operate with mode of tempering to maintain
unoccupied temperature set point.
Service Outlet
120 VAC GFCI service outlet ships loose for fieldinstallation. Requires separate power source so power
is available when unit main disconnect is turned off for
servicing.
Vapor Tight Lights
Vapor tight lights provide light to each of the
compartments in the energy recovery unit. The lights
are wired to a junction box mounted on the outside of
the unit. The switch to turn the lights on is located in
the unit control center. The switch requires a separate
power source to allow for power to the lights when the
unit main disconnect is off for servicing.
Hot Gas Bypass Valve (standard scroll)
On units equipped with hot gas bypass, hot gas
from the compressor is injected into the liquid line of
the evaporator coil after the thermostatic expansion
valve. This process starts to occur when suction gas
temperatures drop below 28°F, which is 32°-34°F coil
surface temperature. Hot gas helps the evaporator coil
from freezing up and the compressor from cycling. The
valve needs to be adjusted to exact specifications once
unit is installed in the field.
Digital Scroll Compressor - PDX Only
Refrigeration Modulation
Digital scroll compressors modulate the refrigeration
system, increasing performance. A conventional fixed
scroll compressor runs at full load and then shuts down
when user set points are reached. The digital scroll
compressor modulates its cooling capacity (10-100%)
by means of cycling through rapid load/no-load cycles
without shutting down the compressor motor (digital
control). Because it can operate at less than full load,
evaporator coil temperatures are much more constant
as hysteresis is improved and humidity control is
enhanced.
Electronic Control
The use of a digital
scroll compressor also
requires a controller.
This controller may be
found in the compressor
compartment of the unit.
The controller works
in conjunction with a
microprocessor controller and requires an analog input.
The controller is pre-programmed and wired and does
not require any further servicing by the owner. Detailed
information on the electronic control circuitry will be
found on the unit-specific wiring diagram in the control
center. The controller constantly monitors and controls
the operation of the digital scroll compressor. LED
indicator lights verify the presence of power, operation
of the unloader solenoid and also indicate various alarm
conditions.
Two Compressor Operation Concept
Whenever two compressors are used in a unit, the
digital scroll compressor is part of refrigerant circuit “A”.
A conventional fixed scroll compressor is used for circuit
“B”. The controller requires a 1 VDC signal to verify
control connection at all times. The minimum input
signal that will cause the compressor to run is 1.9 volts
and the maximum is 5 volts (100% cooling). Whenever
there is a call for cooling, circuit A will be activated first.
Circuit A will provide all necessary cooling until the call
for cooling exceeds 50%. When the call for cooling
reaches 50%, the digital scroll will shut down and the
fixed scroll compressor will begin running. Once the
call for cooling exceeds 70%, then the digital scroll will
begin running again, in conjunction with the fixed scroll
compressor.
VersiVent Energy Recovery Ventilator 19
Cooling System Overview
Packaged DX Cooling with Digital Scroll Compressor
6
4
Condenser Airflow
8
6
3
S
5
2
4
1
Supply
Airflow
10
4
9
2. High Limit Pressure Switch
The switch opens when refrigerant pressure
increases above the set point in the liquid line and
it then requires a manual reset.
3. Hot Gas Reheat Valve (optional)
Units equipped with a reheat coil use a threeway valve with actuator to control the supply
air discharge temperature of the unit during
dehumidification mode. The unit controller provides
a 0-10 VDC signal to control the amount of reheat
to meet the supply temperature set point.
5. Hot Gas Reheat Check Valve
6. Condenser Fans
7. Condensing Coil
8. Liquid Receiver (optional)
20 VersiVent Energy Recovery Ventilator
14
13
11
1. Compressor
4. Hot Gas Reheat Coil
12
9. Sight Glass
10. Liquid Line Filter Drier
11. Thermostatic Expansion Valve (TXV)
Each unit is equipped with a TXV on each
refrigerant circuit. The valve controls the flow of
liquid refrigerant entering the evaporator coil by
maintaining a constant, factory-set superheat of
10°F. The valve is adjustable and is located on the
side of the evaporator coil and can be accessed
through the inner coil access panel.
12. Evaporative Coil
13. Low Limit Pressure Switch
The switch is installed in the suction line and
disables the DX system when the suction pressure
drops below the set point. The switch will autoreset when the pressure rises above the auto-reset
set point.
Start-Up Unit
SPECIAL TOOLS REQUIRED
DANGER
Electric shock hazard. Can cause injury or death.
Before attempting to perform any service or
maintenance, turn the electrical power to unit to OFF
at disconnect switch(es). Unit may have multiple
power supplies.
CAUTION
Use caution when removing access panels or other
unit components, especially while standing on a
ladder or other potentially unsteady base. Access
panels and unit components can be heavy and
serious injury may occur.
CAUTION
Do not operate without the filters and birdscreen
installed. They prevent the entry of foreign objects
such as leaves, birds, etc.
CAUTION
Do not run unit during construction phase. Damage to
internal components may result and void warranty.
WARNING
• Unit was factory tested. All blowers, fans, and
compressors are set-up to run correctly when
supplied power. If any one fan is running backwards
or the compressor is making loud noises,
immediately turn off the power. Switch two leads
on the incoming power to the disconnect. This
will ensure proper operation of the unit. Failure to
comply may damage the compressors and void the
warranty.
• Do not jumper any safety devices when operating
the unit. This may damage components within or
cause serious injury or death.
• Do not operate compressor when the outdoor
temperature is below 40°F.
• Do not short-cycle the compressor. Allow 5 minutes
between “on” cycles to prevent compressor
damage.
• Prior to starting up the unit, power must be
energized for 24 hours without a call for cooling to
allow the compressor crankcase heaters time to boil
off any liquid refrigerant present in the compressor.
• DX system is charged with refrigerant. Start-up must
be performed by EPA Certified Technician.
•
•
•
•
•
•
Voltage Meter (with wire probes)
Amperage Meter
Pressure Gauges – (refrigerant)
Tachometer
Thermometer
U-tube manometer or equivalent
Start-Up Procedure
The unit will be in operational mode during start-up. Use
necessary precautions to avoid injury. All data must be
collected while the unit is running. In order to measure
volts and amps, the control center door needs to be
open and the unit energized.
• Make sure Pre-Start-Up checklist is complete.
• Jumper R to G to enable unit. Jumper R to Y1 and R
to Y2 to enable cooling and R to W1 to enable heat
for units without microprocessor.
• Turn the disconnect on. After 3 minutes,
compressors will come on. Make sure all fans and
compressors are rotating the correct direction.
• Allow the unit to run until the refrigerant system
stabilizes. Approximately 10-15 minutes.
Voltage Imbalance
In a three-phase system, excessive voltage imbalance
between phases will cause motors to overheat and
eventually fail. Maximum allowable imbalance is 2%.
To determine voltage imbalance, use recorded voltage
measurements in this formula.
Key:
V1, V2, V3 = line voltages as measured
VA (average) = (V1 + V2 + V3) / 3
VD = Line voltage (V1, V2 or V3) that
deviates farthest from average (VA)
Formula: % Voltage Imbalance = [100 x (VA-VD)] /VA
VersiVent Energy Recovery Ventilator 21
†
Check the fan belt drives for proper alignment and
tension.
†
Filters can load up with dirt during building
construction. Replace any dirty pleated filters and
clean the aluminum mesh filters in the intake hood.
†
Verify that non-motorized dampers open and close
properly.
†
Check the tightness of all electrical wiring
connections.
†
Verify control wire gauge.
†
Verify diameter seal settings on the energy recovery
wheel.
Unit Serial No. _____________________________________
†
Verify proper drain trap installation.
Heat Pump Model No. ______________________________
†
Check condensing fans for any damage or
misalignment. Spin the blades and make sure they
don’t contact any parts and are free-turning without
any resistance.
†
Look over the piping system. Inspect for oil at all
tubing connections. Oil typically highlights a leak in
the system.
†
Inspect all coils within the unit. Fins may get
damaged in transit or during construction. Carefully
straighten fins with a fin comb.
†
If there is an indirect gas-fired furnace in this unit,
refer to the manual provided with this unit for PreStart-Up information.
†
This unit contains a crankcase heater for each
compressor which needs power supplied to it
24 hours prior to start-up. If start-up is scheduled
in 24 hours, unlock the disconnect power and
energize unit.
Pre Start-Up Checklist
Every installation requires a comprehensive start-up
to ensure proper operation of the unit. As part of that
process, the following checklist must be completed and
information recorded. Starting up the unit in accordance
with this checklist will not only ensure proper operation,
but will also provide valuable information to personnel
performing future maintenance. Should an issue arise
which requires factory assistance, this completed
document will allow unit experts to provide quicker
resolve. Qualified personnel should perform start-up to
ensure safe and proper practices are followed.
Unit Model No. ____________________________________
Energy Wheel Serial Number ________________________
Compressor 1 Model No____________________________
Compressor 2 Model No. ___________________________
Start-Up Date _____________________________________
Start-Up Personnel Name __________________________
Start-Up Company _________________________________
Phone Number ____________________________________
Pre Start-Up Checklist
†Disconnect and lock-out all power switches.
†
Remove any foreign objects that are located in the
energy recovery unit.
†
Check all fasteners, set-screws, and locking collars
on the fans, bearings, drives, motor bases and
accessories for tightness.
†
Check fan rotation.
†
Rotate the fan wheels and energy recovery wheels
by hand and ensure no parts are rubbing.
Start-Up Checklist
Line Voltage. Check at unit disconnect.
L1-L2
Volts
L2-L3
Volts
L1-L3
Volts
Motor Amp Draw
Supply Motor Amps
L1
Amps
L2
Amps
L3
Amps
Exhaust Motor Amps
L1
Amps
L2
Amps
L3
Amps
L3
Amps
Fan RPM
Correct fan rotation direction?
Supply Fan
RPM
Measured Airflow
CFM
Exhaust Fan
RPM
Measured Airflow
CFM
Supply Fan
Yes / No
Exhaust Fan
Yes / No
Energy Wheel Motor
L1
22 VersiVent Energy Recovery Ventilator
Amps
L2
Amps
Heating System / Electric Heat
Pre-Heater
L1-L2
L1
Volts
L2-L3
Amps
L2
Volts
Amps
L1-L3
Volts
L3
Amps
Temp. Rise
Post-Heater
L1-L2
L1
Volts
L2-L3
Amps
L2
Volts
Amps
L1-L3
Volts
L3
Amps
Temp. Rise
Cooling System
Outdoor Air Temperature
Deg F
Outdoor Air Relative Humidity
% RH
Return Air Temperature
Deg F
Return Air Relative Humidity
% RH
Condensing Fan 1
Condensing Fan 2
Condensing Fan 3
L1 ____________ Amps
L1 ____________ Amps
L1 ____________ Amps
L2 ____________ Amps
L2 ____________ Amps
L2 ____________ Amps
L3 ____________ Amps
L3 ____________ Amps
L3 ____________ Amps
Compressor 1
Compressor 1
Hot gas reheat valve
closed
Hot gas reheat valve
open
Compressor 2
L1 ____________ Amps
L1 ____________ Amps
L1 ____________ Amps
L2 ____________ Amps
L2 ____________ Amps
L2 ____________ Amps
L3 ____________ Amps
L3 ____________ Amps
L3 ____________ Amps
Crankcase
heater _________ Amps
Crankcase
heater _________ Amps
Crankcase
heater _________ Amps
Cooling
HP Heating
Cooling
Cooling
HP Heating
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
A. Discharge Pressure
B. Discharge Pressure Converted to
Temperature
C. Liquid Line Temperature
D. Subcooling (B-C)
Should be between 12º and 17ºF
E. Suction Line Pressure
F. Suction Line Temperature
G. Suction Pressure Converted to
Temperature
H. Superheat (F-G)
Should be between 8º and 12ºF
Water In
Water Out
Hot Gas Bypass Operational
(Not present on digital scroll compressors)
Suction Pressure Set Point
Compressor Sight Glass
Oil Level
Oil Foaming
VersiVent Energy Recovery Ventilator 23
Optional Accessories Checklist
Refer to the respective sections in this Installation, Operation and Maintenance Manual for detailed information.
Refer to wiring diagram in unit control center to determine what electrical accessories were provided.
Frost Control Application / Operation Section:
Yes
No
Setting
Factory Default
Frost Control set point
5°F
Differential
2°F
Timer
Yes
No
Refer to IOM
Frost Control Modulating
Refer to IOM
Economizer Application / Operation Section:
Yes
Yes
No
No
Economizer (temperature)
Set point
65°F
Offset
20°F
Differential
2°F
Economizer (enthalpy)
Set point
Yes
No
B
Economizer (modulating)
Refer to IOM
Optional Accessories Section:
Operational
Yes
No
Wheel Rotation Sensor
(1⁄8 in. from wheel)
Yes
No
N/A
Yes
No
OA Dirty Filter Sensor
Yes
No
N/A
Yes
No
EA Dirty Filter Sensor
Yes
No
N/A
Yes
No
No
N/A
No
CO2 Sensor
Service Outlet
Yes
Yes
Yes
No
N/A
Yes
No
Vapor Tight Lights
Yes
No
N/A
Yes
No
Remote Control Panel
Yes
No
N/A
Variable Frequency Drives Section:
Operational
Yes
No
Blower VFDs
Yes
No
N/A
Yes
No
Wheel VFD
Yes
No
N/A
Damper Section:
Operational
Yes
No
Outdoor Air Damper
Yes
No
N/A
Yes
No
Exhaust Air Damper
Yes
No
N/A
Yes
No
Night Setback Damper
Yes
No
N/A
Indirect Gas Furnace:
Yes
No
Refer to PVF/PVG Installation, Operation and Maintenance for start-up information.
24 VersiVent Energy Recovery Ventilator
Start-Up Components
Supply Fan (Plenum Type)
Energy Wheel
The energy wheel is installed in the unit’s airstream with
one half of the wheel in the intake airstream and one
half in the return airstream. Air leakage between the two
airstreams has to be kept to a minimum and the wheel
has air seals that must be adjusted for that purpose.
The seals must be adjusted at time of start-up.
Drive Belt
Inspect the drive belt. Make sure the belt rides smoothly
in the pulley and around the outside of the wheel. Note
the directional arrow and data information shown in the
Bearing Support
image.
Adjustable Air
Seals
The unit contains one plenum supply fan located on
the end of the unit opposite the outdoor air intake and
may optionally have a relief air blower which is referred
to as an exhaust blower in this document. Efficient fan
performance can be maintained by having the correct
offset.
Offset: Proper offset, or overlap, is
adjusted by loosening the wheel hub
from the shaft and moving the wheel
to the desired position along the shaft.
The transition between the inlet cone
and the wheel should
be as shown; there is
Wheel
a smooth feel to the
Offset
profile when moving
Inlet
one component to the
Cone
other.
Unit
Label showing
cassette serial number
and date code
Drive Belt
Offset
(inches)
Tolerance
(inches)
QEP-15
5
± 1⁄8
QEP-18
63⁄8
± 1⁄8
QEP-18
63⁄8
± 1⁄8
QEP-20
7
± 3⁄16
QEP-20
7
± 3⁄16
QEP-24
85⁄8
± 1⁄4
VER-45
VER-65
Drive Pulley
Adjust the Air Seals
VER-90
The first step in wheel seal adjustment is to make sure
the unit power supply is locked
out. Disconnect the wiring to
the wheel module and pull
the wheel cassette out of the
cabinet on its tracks. Large
cassettes are not removable.
Then slowly rotate the wheel by
hand to make sure there is no
Rettaining
ng
binding or misalignment. The
Scr
c ews
s
wheel should rotate smoothly
and should not bind.
There is a perimeter seal
located around the outside of
the wheel and a diameter seal
across the face of the wheel on
both sides. Check to make sure
that all air seals are secure and
in good condition.
Fan
Exhaust Fan
CAUTION
When operating conditions of the fan are to be
changed (speed, pressure, temperature, etc.), consult
manufacturer to determine if the unit can operate
safely at the new conditions.
The unit contains two forward-curved exhaust fans
located on each side of the unit. These forward-curved
fans should be checked for free rotation. If any binding
occurs, check for concealed damage and foreign
objects in the fan housing.
Fan Performance Modifications
Bearing Support Bar
Showing air seal assembly
Adjust the air seals by loosening all the air seal retaining
screws on the bearing support (see image for reference).
Using a piece of paper as a feeler gauge, adjust the
seals so they almost touch the face of the wheel while
tugging slightly on the paper. When the wheel is rotated,
there should be a slight tug on the paper. Tighten the
screws, repeat the steps on the other set of seals.
Push the wheel cassette back into the unit and plug
in the power connector. Turn the main power supply
back on and then observe the operation of the wheel by
opening the wheel access door slightly. Remove filters if
necessary to observe the wheel.
Due to job specification revisions, it may be necessary
to adjust or change the sheave or pulley to obtain the
desired airflow at the time of installation. The start-up
technician must check blower amperage to ensure that
the amperage listed on the motor nameplate is not
exceeded. Amperage to be tested with access doors
closed and ductwork installed.
Fan Belt Drives
The fan belt drive components, when supplied by
manufacturer, have been carefully selected for the
unit’s specific operating condition. Utilizing different
components than those supplied could result in unsafe
operating conditions which may cause personal injury or
failure of the following components:
• Fan Shaft
• Bearings
• Motor
• Fan Wheel
• Belt
VersiVent Energy Recovery Ventilator 25
Tighten all fasteners and set screws securely and realign
drive pulleys after adjustment. Check pulleys and belts
for proper alignment to avoid unnecessary belt wear,
noise, vibration and power loss. Motor and drive shafts
must be parallel and pulleys in line (see diagrams in Belt
Drive Installation section).
Belt Drive Installation
straightedge
centerline
1. Remove the protective coating from the
0.25 in.
end of the fan shaft and assure that it is
free of nicks and burrs.
1.5 in.
2. Check fan and motor shafts for parallel
and angular alignment.
3. Slide sheaves on shafts. Do not drive
sheaves on as this may result in bearing
damage.
4. Align fan and motor sheaves with a
straightedge to centerline.
5. Place belts over sheaves. Do not pry
or force belts, as this could result in
damage to the cords in the belts.
2 in.
6. With the fan off, adjust the belt tension
by moving the motor base. (Refer to Fan Pulley
Belts for proper tensioning procedures alignment
example
in the Routine Maintenance section of
this manual). When in operation, the
tight side of the belts should be in a straight line from
sheave to sheave with a slight bow on the slack side.
Fan RPM
Supply fan and exhaust fan will have an adjustable
motor pulley (on 15 HP and below) preset at the factory
to the customer-specified RPM. Fan speed can be
increased or decreased by adjusting the pitch diameter
of the motor pulley. Multi-groove variable pitch pulleys
must be adjusted an equal number of turns open
or closed. Any increase in fan speed represents a
substantial increase in load on the motor. Always check
the motor amperage reading and compare it to the
amperage rating shown on the motor nameplate when
changing fan RPM. All access doors must be installed
except the control center door.
WARNING
Do not operate units with access doors open or
without proper ductwork in place as the fan motors
will overload.
Vibration
Excessive vibration may be experienced during initial
start-up and can cause a multitude of problems,
including structural and/or component failure.
Vibration Causes
Off axis or loose components
Drive component unbalance
Poor inlet / outlet conditions
Foundation stiffness
Many of these conditions
can be discovered by
careful observation. Refer
to the Troubleshooting
section of this manual for
corrective actions.
If observation cannot locate the source of vibration, a
qualified technician using vibration analysis equipment
should be consulted. If the problem is wheel unbalance,
in-place balancing can be done.
WRONG
WRONG
WRONG
CORRECT
Proper alignment of motor and drive shaft.
Direction of Fan Wheel Rotation
Blower access is labeled on unit. Check for proper
wheel rotation by momentarily energizing the fan.
Rotation is determined by viewing the wheel from the
drive side and should match the rotation decal affixed to
the fan housing.
If the wheel is rotating the wrong way, direction can be
reversed by interchanging any two of the three electrical
leads. Check for unusual noise, vibration, or overheating
of bearings. Refer to the Troubleshooting section of this
manual if a problem develops.
Rotation
Rotation
Airflow
Forward Curved
26 VersiVent Energy Recovery Ventilator
Generally, fan vibration and noise is transmitted to other
parts of the building by the ductwork. To eliminate this
undesirable effect, the use of heavy canvas connectors
is recommended.
Hot Gas Bypass Valve (standard scroll)
To adjust, connect a pressure gauge to the suction line
and block the entering air to the evaporator coil. The
valve should begin to open when the suction pressure
drops to approximately 115 PSIG for R-410A (the valve
will feel warm to the touch). Adjustments are made by
first removing the cap on the bottom of the valve and
then turning the adjusting stem clockwise to increase
the setting pressure (counterclockwise to decrease).
Allow several minutes between adjustments for the
system to stabilize. When adjustment is complete,
replace the cap on the valve.
Optional Components Start-Up
Dirty Filter Sensor
To adjust the sensor, the unit must be running with
all of the access doors in place, except for the
compartment where the sensor is located (exhaust
intake compartment). The adjusting screw is located on
the top of the switch.
Setscrew (on front of switch) must
be manually adjusted after the
system is in operation.
Negative pressure connection
is toward the ‘front or top’ of
the sensor. (Senses pressure on
the blower side of filters)
Positive pressure connection is toward the ‘back or bottom’
of the switch. (Senses pressure at air inlet side of filters)
1. Open the filter compartment and place a sheet of
plastic or cardboard over 50% of the filter media.
2. Replace the filter compartment door.
3. Check to see if there is power at the alert signal
leads (refer to electrical diagram).
4. Whether there is power or not, turn the adjustment
screw on the dirty filter gauge (clockwise if you did
not have power, counterclockwise if you did have
power) until the power comes on or just before the
power goes off.
5. Open the filter compartment and remove the
obstructing material.
6. Replace the door and check to make sure that you
do not have power at the alert signal leads. The unit
is now ready for operation.
Economizer
Relevant Set Points
1. MAT SET The mixed air temperature set point after
the energy wheel. The control will modulate the
energy wheel to maintain temperature as best as it
can. (Set point menu, default 53°F)
2. LOW T LOCK The set point for the low temperature
mechanical cooling lockout. (Set point menu, default
32°F)
3. DRYBLB SET The outdoor air set point to call for
economizer. (Set point menu, default 63°F)
4. MIN POS The minimum signal voltage sent to the
energy wheel. This must be set to 2 VDC. (Set point
menu, default 2.8 VDC)
5. AUX1 O The controllers operating sequence
structure. (Set point menu, default ‘None’)
6. ERV OAT SP The set point for low temperature
economizer lockout. This is the low temperature set
point when AUX1 O is set to ERV. (Set point menu,
default 32°F)
7. STG3 DLY Time delay after second cooling stage is
enabled. (Advanced setup menu, default 2 hrs.)
Using the Keypad with Settings and Parameters
To use the keypad when working with Set Points,
System and Advanced Settings, Checkout Tests, and
Alarms:
1. Navigate to the desired menu.
2. Press (enter) to display the first item in the
currently displayed menu.
3. Use the and
parameter.
buttons to scroll to the desired
4. Press (enter) to display the value of the currently
displayed item.
5. Press the button to increase (change) the
displayed parameter value.a
6. Press the button to increase (change) the
displayed parameter value.a
7. Press (enter) to accept the displayed value and
store it in non-volatile RAM.
8. CHANGE STORED displays.
9. Press (enter) to return the current menu
parameter.
10. Press
(escape) to return to the current menu
parameter.
a When values are displayed, pressing and holding the
or button causes the display to automatically
increment.
The table on the following page shows which set points
are relevant to the given sequences. Refer to the wiring
diagram for the units’ sequence.
VersiVent Energy Recovery Ventilator 27
MODULATE WHEEL
OA
OA
Temp Enthalpy
STOP WHEEL
OA/RA
OA/RA
OA
OA
Temp
Temp
Temp Enthalpy
Differential
Differential
DRYBLB SET
X
MAT SET
X
X
X
X
X
X
X
LOW T LOCK
X
X
X
X
X
X
X
X
X
X
X
X
ERV
ERV
ERV
X
X
X
X
X
X
ERV OAT SP
MIN POS
AUX1 OUT
STG3 DLY
Stop Wheel
1. Navigate to the Checkout menu and press (enter).
2. The energy wheel and cooling should stop.
3. Navigate to Connect ERV and press (enter) twice
to run the test.
4. Voltage between AUX1 O and C should be 24 VAC.
The energy wheel should activate.
Modulate Wheel
1. Navigate to the Checkout menu and press (Enter).
2. The cooling should turn off and the wheel should be
rotating at full speed.
3. Navigate to Damper Open and press (enter) twice
to run the test.
4. Voltage between terminals ACT 2-10 and ACT COM
should be 10 VDC. This will slow the wheel down to
minimum speed.
5. Press
(escape), navigate to Damper Close and
press (enter) twice to run the test.
6. Voltage between terminal ACT 2-10 and ACT COM
should be 2 VDC. This will speed the wheel up to
maximum speed.
28 VersiVent Energy Recovery Ventilator
Frost Control
Timed Exhaust
1. Remove power from unit.
2. Jumper the frost indicating wheel pressure switch in
the unit control center.
3. Jumper the temperature indicating thermodisc in
the unit control center. Thermodisc has a pre-set
temperature of 5°F.
4. Set the frost control timer scale for T1 and T2 to 1m.
Set the timer settings for T1 and T2 to 10.
5. Add power to the unit. Blower should cycle on for
one minute, then turn off for one minute.
6. Remove power from unit and remove jumpers that
were placed. Reset timer settings.
• T1 timer
setting set to
5 and timer
scale set to
10m for 5
Timer
T1
Scale
minutes of
Settings
wheel off time.
Timer
Settings
• T2 timer
T2
setting set to
Settings
Timer
5 and timer
Scale
scale set to 1h
for 30 minutes
of wheel on
time.
Electric Preheat
1. Remove power from unit.
2. Jumper the frost indicating wheel pressure switch in
the preheat control center.
3. Jumper the temperature indicating thermodisc in
the preheat control center. Thermodisc has a pre-set
temperature of 5° F.
4. Apply power to unit. Preheater should turn on.
Variable Frequency Drives
Factory Set Points
Optional factory-installed, wired, and programmed
variable frequency drives (VFDs) may have been
provided for modulating or multi-speed control of the
blowers and energy recovery wheel for economizer and
frost control modes. One VFD, either Yaskawa model
V1000 or J1000, is provided for each blower (supply air
and exhaust) and one Yaskawa model J1000 is provided
for the energy recovery wheel.
Variable frequency drives (VFDs) for the blowers are
factory set to operate in one of the three following
modes:
• Modulating: 0-10 VDC signal wired in the field by
others varies the speed of the blower between 30
and 60 Hz
• Multi-speed: Digital contact closures by others
command the VFD to run at multiple speed settings:
- Open - Drive runs at 60 Hz
- SC to S4 - Drive runs at 40 Hz
- SC to S5 - Drive runs at 30 Hz
• CO2 Sensor:
Set Point Control: A carbon dioxide sensor is
provided from the factory for field-mounting in the
space(s) being served by the energy recovery unit.
The CO2 sensors are wired to the unit VFD’s with
two preset speeds of 700 PPM or less CO2 = 50%
fan speed and 800 PPM or greater CO2 = 100%
fan speed.
Proportional Control: A carbon dioxide sensor is
provided from the factory for field-mounting in the
space(s) being served by the energy recovery unit.
The CO2 sensors are wired to the unit VFD’s with
default factory settings of 500 PPM or less CO2
= 50% fan speed and 1000 PPM or greater CO2
= 100% fan speed. Modulation of VFD occurs
proportional to CO2 between 500 and 1000 PPM.
Most of the set points in the VFDs are Yaskawa factory
defaults. However, a few set points are changed at
Greenheck and are shown in the tables. These settings
are based on the VFD mode selected.
Refer to the tables in this section for factory settings
and field-wiring requirements. Refer to the unit control
center for unit specific wiring diagram. When making
adjustments outside of the factory set points, refer to
Yaskawa VFD instruction manual, which can be found
online at www.drives.com. For technical support,
contact Yaskawa direct at 1-800-927-5292.
R+ R- S+ S- IG
P1 P2 PC A1 A2 +V AC AM AC MP
S1 S2 S3 S4 S5 S6 S7 HC SC H1 RP
MA MB MC
S1 S2 S3 S4 S5 SC A1 +V AC AM AC
MA MB MC
J1000
V1000
A1 AC
0-10 VDC CONTROL SIGNAL (BY OTHERS)
WIRED TO A1 (+) AND AC (COMMON)
0 VDC=30 Hz
10 VDC=60 Hz
FOR ONE 0-10 SIGNAL, WIRE TO DRIVES IN PARALLEL
SEE VFD INSTALLATION MANUAL FOR MORE DETAIL
FOR CONTINUOUS 60Hz OPERATION JUMPER TERMINALS A1 AND +V.
OPTION 2 - MULTI SPEED CONTROL
USER TO PROVIDE CONTACTS AND ISOLATION
AS REQUIRED
S4 S5 SC
NEITHER S4 OR S5 CONTACT CLOSED
DRIVE SPEED = 60 Hz.
S4 TO SC CONTACT CLOSED (BY OTHERS)
DRIVE SPEED = 40 Hz.
Change Set Points
To gain access to change set points on the V1000 and
J1000 drives, parameter A1-01 needs to be set at “2”.
To prevent access or tampering with drive settings on
either drive, change parameter A1-01 to “0”.
• Drive Operation
- SC to S1 contact for On/Off
- A1 (0-10 VDC) referenced to AC
Can use +15 VDC from +V
Resetting the V1000 drive to factory defaults
To reset the V1000 drive back to Greenheck factory
defaults, go to parameter A1-01 and set it to “2”. Then
go to A1-03 and change it to “1110” and press enter.
The drive is now reset back to the settings programmed
at Greenheck. This option is not available on the J1000.
S5 TO SC CONTACT CLOSED (BY OTHERS)
DRIVE SPEED = 30 Hz.
SEE VFD INSTALLATION MANUAL FOR MORE DETAIL
TO CHANGE THE FACTORY SET Hz CHANGE THE FOLLOWING PARAMETERS.
PARAMETER A1-01 CHANGE TO 2
PARAMETER d1-01 FOR NEW 60Hz SETTING
PARAMETER d1-02 FOR NEW 40Hz SETTING
PARAMETER d1-03 FOR NEW 30Hz SETTING
PARAMETER A1-01 CHANGE TO 0
VersiVent Energy Recovery Ventilator 29
Modulating Control for Fan Speed
CO2 Proportional Control
(0-10 VDC)
Parameter
Setting
Parameter
V1000
J1000
A1-01
Access Level
2
2
B1-17
VFD Start-Up Setting
Setting
V1000
J1000
1
1
B1-17
VFD Start-Up Setting
1
1
C6-02
Carrier Frequency
1
1
C6-02
Carrier Frequency
1
1
D2-02
Ref Lower Limit
50%
50%
D2-02
Ref Lower Limit
50%
50%
E2-01
Motor Rated FLA
FLA
FLA
150%
150%
E2-01
Motor Rated FLA
Motor
FLA
Motor
FLA
H3-03
Analog Frequency Reference
(Gain)
H2-01
Terminal MA, MC Function
5
5
H3-04
25%
25%
H3-04
Terminal A1 Bias
50%
50%
Analog Frequency Reference
(Bias)
L4-01
H2-01 Frequency Detection
15
15
L2-01
Ride Thru Power Loss
2
2
L5-01
Auto Restart Attempt
5
5
L4-05
Frequency Ref Loss
0
NA
A1-01
Access Level
0
0
L5-01
Auto Restart Attempt
5
5
A1-01
Access Level
0
0
CO2 Sensor Control for Fan Speed
Variable Frequency Drives for
Energy Recovery Wheel
(1/2 speed when CO2 drops below 700 PPM)
(Full speed when CO2 rises above 800 PPM)
Parameter
Multi-Speed Control for Fan Speed
(1/3 or 1/2 speed reduction)
Parameter
A1-01
Access Level
Setting
A1-01
Access Level
2
B1-17
VFD Auto Start
1
C1-04
Decel Time
600
Torque Gain
0.6
V1000
J1000
*C4-01
2
2
C6-02
Carrier Frequency
2
D2-01
Ref Upper Limit
40 or 50*
D2-02
Ref Lower Limit
5%
E2-01
Motor Rated FLA
Motor FLA
E2-03
Motor No-Load Current
Must be less
than FLA
H1-02
Multi-Function Input
(Terminal S2)
6
H2-01
Multi-Function Output
(MA, MB, MC)
4
H1-04
Multi-Function Input Sel 4
(Terminal S4)
7
B1-01
Reference Source (Frequency)
0
0
B1-17
VFD Start-Up Setting
1
1
C6-02
Carrier Frequency
1
1
D1-01
Frequency Reference 1
60 Hz
60 Hz
D1-02
Frequency Reference 2
40 Hz
40 Hz
D1-03
Frequency Reference 3
30 Hz
30 Hz
D1-04
Frequency Reference 4
60 Hz
60 Hz
D2-02
Ref Lower Limit
50%
50%
E2-01
Motor Rated FLA
Motor
FLA
Motor
FLA
H1-04
Multi-Function Input Sel 4
(Terminal S4)
3
3
H1-05
Multi-Function Input Sel 5
(Terminal S5)
4
4
H1-06
Multi-Function Input Sel 6
(Terminal S6)
5
NA
H2-01
Terminal MA, MC Function
5
5
H3-10
A2 Not Used
F
NA
L4-01
H2-01 Frequency Detection
15
15
L5-01
Auto Restart Attempt
5
5
A1-01
Access Level
0
0
Setting
Economizer Signal Source
(0-10 VDC)
Honeywell
Module
Carel
Controller
H3-03
Analog Frequency Reference
(Gain)
0
40 or
50*
H3-04
Analog Frequency Reference
(Bias)
40 or
50**
0
L1-01
Elect Thermal Overload
2
L2-01
Ride Thru Power Loss
2
L4-01
Frequency Detection Level
15
L5-01
Auto Restart Attempt
5
A1-01
Access Level
0
* 208/230 volt only
**52 inch wheels are 40 (24 Hz)
58 inch wheel is 50 (30 Hz)
30 VersiVent Energy Recovery Ventilator
Setting – J1000
Routine Maintenance
DANGER
Electric shock hazard. Can cause injury or death.
Before attempting to perform any service or
maintenance, turn the electrical power to the unit to
OFF at disconnect switch(es). Unit may have multiple
power supplies.
CAUTION
Use caution when removing access panels or other
unit components, especially while standing on a
ladder or other potentially unsteady base. Access
panels and unit components can be heavy and serious
injury may occur.
This unit requires minimal maintenance to operate
properly. Maintenance requirements for this model
vary for each installation and depend greatly on how
much the system is used and the cleanliness of the air.
Proper maintenance will both increase the life of the
system and maintain its efficiency. Maintenance must
be performed by experienced technicians and in the
case of refrigeration systems, must be done by an EPA
certified technician.
Maintenance frequency is based on a presumed
nominal use of the system. If the system is being
run constantly, the frequency should be adjusted
accordingly. If there is seasonal debris in the air which
can be drawn into the filters and the coils, they should
be checked more frequently. If the system is being
used for only a few hours per day, the frequency may
be reduced. Use the maintenance log at the end of
this manual to record each maintenance session
and observations and then establish a maintenance
schedule that is appropriate for the installation. The
following is provided as a guideline:
Annually
It is recommended that the annual inspection and
maintenance occur at the start of the cooling season.
After completing the checklist, follow the unit startup checklist provided in the manual to ensure the
refrigeration system operates in the intended matter.
1. Lubrication
Apply lubricant where required
2. Dampers
Check for unobstructed operation
3. Blower Wheel and Fasteners
Check for cleanliness
Check all fasteners for tightness
Check for fatigue, corrosion, wear
4. Door Seal
Check if intact and pliable
5. Wiring Connections
Check all connections for tightness
6. Cabinet
Check entire cabinet, inside and out, for dirt
buildup or corrosion. Remove accumulated dirt,
remove any surface corrosion and coat the area
with appropriate finish.
Units with Packaged DX
Semiannually
1. Evaporator Coil Maintenance
Check for cleanliness - clean if required
2. Condenser Coil Maintenance
Check for cleanliness - clean if required
3. Condensate Drain
Inspect and clean - refill with water
4. Condensing Fan Blades and Motors
Check for cleanliness
Check all fasteners for tightness
Check for fatigue, corrosion and wear
Maintenance Frequency
Monthly
1. External Filter
Clean metal mesh filters
2. Internal Filters
Replace MERV 8 filters monthly.
Adjust replacement schedule for MERV 13 or
other filters as inspection requires.
Semiannually
1. Check motor and motor bearings
Check for excessive heat, vibration or noise.
Lubricate bearings in accordance with the motor
manufacturer’s recommendations.
2. Condensate Drain (if applicable)
Inspect and clean – refill with water
3. Condenser Coils
Inspect for cleanliness – clean as required
VersiVent Energy Recovery Ventilator 31
Maintenance Procedures
WARNING
REFER TO GENERAL SAFETY INFORMATION
Do not operate this unit without the filters and
birdscreen installed. They prevent the entry of foreign
objects such as leaves, birds, etc.
Do not remove access panels or other unit
components while standing on a ladder or other
unsteady base. Access panels and unit components
are heavy and serious injury may occur.
Lubrication
Check all moving components for proper lubrication.
Apply lubricant where required. Any components
showing excessive wear should be replaced to maintain
the integrity of the unit and ensure proper operation.
Dampers
Check all dampers to ensure they open and close
properly and without binding. Backdraft dampers can
be checked by hand to determine if blades open and
close freely. Apply power to motorized dampers to
ensure the actuator opens and closes the damper as
designed.
Gas Furnace
Maintain furnace in accordance with instructions in the
Indirect Gas-Fired Heat IOM shipped with this unit.
Fan Belts
Belts must be checked on a regular basis for wear,
tension, alignment, and dirt accumulation. Premature
or frequent belt failures can be caused by improper
belt tension (either too loose or too tight) or misaligned
sheaves. Abnormally high belt tension or drive
misalignment will cause excessive bearing loads and
may result in failure of the fan and/or motor bearings.
Conversely, loose belts will cause squealing on start-up,
excessive belt flutter, slippage, and overheated sheaves.
Both loose and tight belts can cause fan vibration.
When replacing belts on multiple groove drives, all belts
should be changed to provide uniform drive loading. Do
not pry belts on or off the sheave. Loosen belt tension
until belts can be removed by simply lifting the belts off
the sheaves. After replacing belts, ensure that slack in
each belt is on the same side of the drive. Belt dressing
should never be used.
Do not install new belts
on worn sheaves. If the
sheaves have grooves
worn in them, they must
be replaced before new
belts are installed.
Deflection = Belt Span
64
Fan Motors
Motor maintenance is generally limited to cleaning
and lubrication. Cleaning should be limited to exterior
surfaces only. Removing dust and grease buildup on
the motor housing assists proper cooling. Never washdown the motor with high pressure spray. Greasing
of motors is only intended when fittings are provided.
Fan motors typically have two grease fittings. Each
motor manufacturer has different lubrication schedules
for different models. Go to the motor manufacturer’s
website and download their maintenance requirements.
Do not over-lubricate motors or use an incompatible
grease. Many fractional motors are permanently
lubricated for life and require no further lubrication.
Fan Wheel and Fasteners
Wheels require very little attention when moving clean
air. Occasionally oil and dust may accumulate on the
wheel causing imbalance. When this occurs, the wheel
and housing should be cleaned to assure smooth and
safe operation. Inspect fan impeller and housing for
fatigue, corrosion, or wear.
Routinely check all fasteners, set screws and locking
collars on the fan, bearings, drive, motor base and
accessories for tightness. A proper maintenance
program will help preserve the performance and
reliability designed into the fan.
Bearings
Most bearings are permanently lubricated and require
no further lubrication under normal use. Normal use
being considered -20° to 120°F and in a relatively clean
environment. Some bearings are relubricatable and will
need to be regreased depending on fan use. Check your
bearings for grease zerk fittings to find out what type
of bearing you have. If your fan is not being operated
under normal use, bearings should be checked monthly
for lubrication.
Shaft bearings are the most critical moving part of a
fan. Therefore, special attention should be given to
keeping the bearings clean and well lubricated. Proper
lubrication provides for reduction in friction and wear,
transmission and dissipation of heat, extended bearing
life and prevention of rust.
In order for a lubricant to fulfill these tasks, the proper
grease applied at regular intervals is required.
Belt Span
The proper belt setting
is the lowest tension at which the belts will not slip
under peak load operation. For initial tensioning, set
the belt deflection at 1/64-inch for each inch of belt
span (measured half-way between sheave centers). For
example, if the belt span is 64 inches, the belt deflection
32 VersiVent Energy Recovery Ventilator
should be one inch (using moderate thumb pressure at
mid-point of the drive). Check belt tension two times
during the first 24 hours of operation and periodically
thereafter.
If unusual conditions exist—temperatures below 32°F or
above 200°F, moisture or contaminants—more frequent
lubrication is required.
With the unit running, add grease very slowly with a
manual grease gun until a slight bead of grease forms at
the seal.
Be careful not to unseat the seal by over lubricating
or using excessive pressure. A guide to the amount
of grease to be used is to fill 30% to 60% of available
space in the bearing and housing.
A high quality lithium based grease conforming to NLGI
Grade 2 consistency should be used.
Internal Filter
The unit will typically be provided with 2-inch thick
pleated paper filters in the airstream. These filters
should be checked according to a routine maintenance
schedule and replaced as necessary to ensure proper
airflow through the unit. Replacement filters shall be of
same performance and quality as factory-installed filters.
Winterizing Coils
Coil freeze-up can be caused by such things as air
stratification and failure of outdoor air dampers and/
or preheat coils. Routine draining of water cooling coils
for winter shutdown cannot be depended upon as
insurance against freeze-up. Severe coil damage may
result. It is recommended that all coils be drained as
thoroughly as possible and then treated in the following
manner.
Filters upstream of the coil should be checked regularly.
If the filters are dirty, they should be cleaned or
replaced. It is important the filters stay clean to maintain
desired airflow.
Fill each coil independently with an antifreeze solution
using a small circulating pump and again thoroughly
drain. Check freezing point of antifreeze before
proceeding to next coil. Due to a small amount of water
always remaining in each coil, there will be diluting
effect. The small amount of antifreeze solution remaining
in the coil must always be concentrated enough to
prevent freeze-up.
Internal Filter Size and Quantities
WARNING
Unit
Wheel
Supply
Wheel
Exhaust
Final 2 in.
(optional)
Final 4 in.
(optional)
VER-45 (4) 16x25x2 (4) 16x25x2 (4) 16x25x2 (4) 16x25x4
VER-65 (6) 16x25x2 (6) 16x25x2 (6) 16x25x2 (6) 16x25x4
VER-90 (6) 20x25x2 (6) 20x25x2 (6) 20x20x2 (6) 20x20x4
External Filter
Aluminum mesh, 2-inch thick filters are located in the
supply weatherhood (if the weatherhood option was
purchased). These filters should be checked and cleaned
on a regular basis for best efficiency. The frequency of
cleaning depends upon the cleanliness of the incoming
air. These filters should be cleaned by rinsing with a mild
detergent in warm water prior to start-up.
Carefully read instructions for mixing antifreeze
solution used. Some products will have a higher
freezing point in their natural state than when mixed
with water.
Door Seals
An EPDM foam rubber bulb seal backed with a high
strength acrylic adhesive is installed on the door frame
of the unit. This creates and air tight seal between the
rubber seal and the door. Inspect at least annually to
ensure that the seal is damage free and still intact.
Coils
Coils must be cleaned to maintain maximum
performance. Check coils once per year under normal
operating conditions and if dirty, brush or vacuum clean.
Soiled fins reduce the capacity of the coil, demand
more energy from the fan and create an environment
for odor and bacteria to grow and spread through the
conditioned zone.
WARNING
Biological hazard. May cause disease. Cleaning
should be performed by qualified personnel only.
For coils with fragile fins or high fin density, foaming
chemical sprays and washes are available. Care must
be taken not to damage the coils, including the fins,
while cleaning. Caution: Fin edges are sharp!
Drain pans in any air conditioning unit will have some
moisture in them, therefore, algae and other organisms
will grow due to airborne spores and bacteria. Periodic
cleaning is necessary to prevent this buildup from
plugging the drain and causing the drain pan to
overflow. Inspect twice a year to avoid the possibility
of overflow. Also, drain pans should be kept clean to
prevent the spread of disease.
VersiVent Energy Recovery Ventilator 33
Energy Wheel Maintenance
WARNING
Whenever performing maintenance or inspections,
always disconnect the power source.
Inspection
The wheel should be inspected semiannually
in accordance with the maintenance schedule.
Maintenance of the wheel consists
mainly of inspecting the wheel
for cleanliness and then checking
the drive motor, belt, and pulley
for wear. If the wheel layers
appear dirty, the wheel should be
disassembled and cleaned.
The wheel rotates through the two
airstreams which are moving in
opposite directions, the wheel is
self-cleaning, up to a point. If the
Energy Wheel
Cassette
wheel media becomes blocked by
dirt or dust, or if the media collects a layer of smoke
residue or an oily film, the energy transfer efficiency
drops.
The main factor in the frequency of cleaning is the
cleanliness of the air. If air filters are not changed
frequently, the wheel will collect contaminants and will
then have to be cleaned.
Wheel Disassembly
Wheels are part of a cassette that may be pulled from
the unit for easy access. There may be a small damper
assembly or other components that block removal of
the cassette. Before sliding out the cassette or any other
component, disconnect any power supply cord and
secure it so it cannot jam or otherwise get damaged.
Each wheel has removable segments that hold the
coated layers of media and each segment is held in
place with two retaining
clips located on the outer
rim of the wheel. When
removing more than one
segment, remove them in
Segment Retaining Clip
sequence from opposite
sides of the wheel (180 degrees apart) to reduce the
imbalance. Secure the wheel against rotation. Carefully
release the two retaining clips and swing them fully
open. The segment can now be removed by pushing the
face of the segment close to the outer rim of the wheel.
Wheel segments are built to close tolerances and the
segment may have to be jiggled to remove it. Do not
use a hammer or otherwise force the segment because
these are high value items and are not built to withstand
abuse.
Whenever retaining clips are opened, they should be
closed as soon as possible. If the wheel should rotate
when a clip is open, the clip will jam against the bearing
support bar and could cause damage.
34 VersiVent Energy Recovery Ventilator
Cleaning
Maintenance or cleaning of the wheel segments
should be done with the segments removed from
the wheel cassette to avoid splashing liquids or
cleaning agents inside the cabinet. If the energy wheel
appears excessively dirty, it should be cleaned to
ensure maximum operating efficiency. Only excessive
buildup of foreign materials needs to be removed.
DISCOLORATION AND STAINING OF ENERGY
RECOVERY WHEEL DOES NOT AFFECT ITS
PERFORMANCE.
Thoroughly spray the wheel matrix with a household
cleaner such as Fantastik™ or the equivalent. Gently
rinse with warm water and use a soft brush to remove
any heavy accumulations. A detergent/water solution
can also be used. Avoid aggressive organic solvents,
such as acetone. Wheel segments can be soaked in the
above solution overnight for removal of stubborn dirt or
accumulations.
After cleaning is complete, shake excess water from the
wheel or segments. Dry the wheel or segments before
putting them back into the cassette.
Reassembly
When reinstalling the segments, be sure to install them
with the correct face toward the motor side of the
cassette. Note that one face of each segment is smooth
and the other face has a reinforcing channel or support
cut into the surface.
Wheel Segment
(Pulley Side)
Wheel Segment
(Motor Side)
Wheel Belt
Inspect belts each time filters are replaced. Belts
that look chewed up or are leaving belt dust near the
motor pulley may indicate a problem with the wheel.
Be sure to inspect wheel for smooth and unrestricted
rotation. If a belt requires replacement, contact the
local manufacturer representative. Instructions for
replacement will ship with the new belt.
Wheel Bearing
In the unlikely event that a wheel bearing fails, the
bearing is behind a removable plate on the wheel
support beam. Contact the local manufacturer
representative for detailed instructions on how to
replace the bearing.
Troubleshooting – Unit
Symptom
Blower fails to
operate
One or both
blowers turn off
intermittently and
back on after two
minutes
Motor starters
“chatter” or do not
pull in
Possible Cause
Corrective Action
Blown fuse or open circuit breaker.
Replace fuse or reset circuit breaker and check
amps.
Defective motor or capacitor.
Replace.
Motor overloaded.
Reset VFD and check amps.
Electrical.
Check for On/Off switches. Check for correct
supply voltage. Check Control wiring.
Blower fan motor overloads are tripping and autoresetting.
Decrease fan speed.
Exhaust only frost control sensors are tripping.
Adjust frost temperature sensor set point as
needed.
Control power (24 VAC) wiring run is too long.
(Resistance should not exceed 0.75 ohms).
Shorten wiring run to mechanical room or install a
relay to turn unit on/off. Consult factory for relay
information. Increase wire gauge size so that
resistance is 0.75 ohms or less.
Incoming supply power is less than anticipated.
Voltage supplied to starter coil must be within
+10% / -15% of nominal voltage stated on the coil.
Need to increase supply power or use a special
control transformer which is sized for the actual
supply power.
Static pressures are higher than design.
Check for dirty filters. Improve ductwork.
Motor voltage incorrect.
Check motor wiring. Check motor nameplate
versus supplied voltage.
Motor horsepower too low.
See specifications and catalog for fan curves to
determine if horsepower is sufficient.
Shorted windings in motor.
Replace motor.
Motor over amps
Low airflow (cfm)
High airflow (cfm)
Excessive noise or
vibration
Unit damper not fully open.
Adjust damper linkage or replace damper motor.
System static pressure too high.
Improve ductwork to eliminate losses using good
duct practices.
Blower speed too low.
Check maximum motor RPM and compare with
catalog data. Verify that external control wiring is in
place if required.
Fan wheels are operating backwards.
For 3-phase, see Direction of Fan Wheel Rotation in
Start-Up Components section.
Dirty filter.
Replace filters or follow cleaning procedures in
Routine Maintenance section of this manual.
Leaks in ductwork.
Repair.
Elbows or other obstructions may be obstructing
fan outlet.
Correct or improve ductwork.
Blower fan speed too high.
Check for correct maximum fan RPM. Decrease
maximum fan speed if necessary with the variable
frequency drive.
Filter(s) not in place.
Install filters.
Insufficient static pressure (Ps).
(airflow resistance)
Induce Ps into system ductwork. Make sure grilles
and access doors are installed. Decrease fan speed
if necessary.
Fan wheel rubbing on inlet.
Adjust wheel and/or inlet cone. Tighten wheel hub
or bearing collars on shaft.
Bearings.
Replace defective bearing(s). Lubricate bearings.
Tighten collars and fasteners.
Loose wheel on shaft.
Tighten wheel hub.
Motor base or blower loose.
Tighten mounting bolts.
Noise being transmitted by duct.
Make sure ductwork is supported properly. Make
sure ductwork metal thickness is sized for proper
stiffness. Check duct size at discharge to ensure
that air velocities are not too high.
VersiVent Energy Recovery Ventilator 35
Troubleshooting – Refrigeration Circuit
TROUBLESHOOTING NOTE
Before any components are changed on the
refrigeration system, the cause of the failure must be
identified. Further problems will exist unless the true
cause or problem is identified and corrected.
IMPORTANT
Do not release refrigerant to the atmosphere! If
required service procedures include the adding or
removing of refrigerant, the service technician must
comply with all federal, state and local laws. The
procedures discussed in this manual should only be
performed by a qualified EPA Certified Technician.
NOTE: Unit is equipped with a phase loss/phase reversal control. If system does not start, check phase of electrical
supply.
The first step in troubleshooting a refrigeration circuit is to examine the microprocessor and digital scroll compressor
controller (if present) and see if there is a fault code. The next step is to check airflow conditions (e.g. improper
ductwork, atypical wet bulb / dry bulb, etc.). After these steps have been eliminated, proceed with troubleshooting
by following this guide.
Symptom
Compressor
will not run or
does not start
Compressor
starts but cuts
out on low
pressure
Low pressure
switch
activates at
50 PSIG
Possible Cause
Corrective Action
Open disconnect switch or circuit breaker.
Close switch and/or breaker.
Compressor contactor not closing.
Check voltage to contactor coil, transformer, slave relay,
system. Replace parts as necessary.
Blown fuse or tripped breaker.
Check for reason and repair. Replace fuse after correcting
problem.
Low line voltage.
Check line voltage. If more than 10% from compressor marking,
correcting is necessary.
Compressor motor protector open.
Motor thermal protector automatically resets. Allow time (two
hours) for compressor to cool down so protector will reset.
Restart and check for reason overheat occurred.
Compressor defective.
Check motor for open circuit, short circuit, grounded windings,
or burn out. Compressor may be seized; check refrigerant. If
necessary, replace compressor.
High pressure switch open
or defective.
If manual reset (high pressure), reset switch. (Switch opens at
600 psi and will not reset above 420 psi for R-410A). Replace if
defective.
Low pressure switch open
or defective.
Switch will open at 50 psi and auto-close at 90 psi. Replace if
defective.
Open room thermostat or control.
(No cooling required).
Check room temperature. If temperature is proper, wait for
thermostat to close.
Loose wiring.
Check all wire terminals and tighten as necessary.
Low or loss of refrigerant charge.
Check refrigerant pressures and temperatures (subcooling).
Airflow restricted.
Check for dirty evaporator coil, dirty filters, dampers closed,
iced evaporator coil, improper belt, check motor amps, check
duct design.
Restriction in refrigerant line.
Check refrigerant pressures, look for frosted tubing and
components indicating a restriction. Check pressure drop
across the filter drier.
Defective low pressure switch.
Replace.
Always have a completed Pre-Start-Up Checklist and Start-Up Checklist prior to requesting parts or service
information.
36 VersiVent Energy Recovery Ventilator
Troubleshooting – Refrigeration Circuit
Symptom
Compressor
starts but
cuts out on
high pressure
switch
High pressure
activates at
600 PSIG
Compressor
cuts out
on thermal
overload
Compressor
hums, but will
not start
Compressor
noisy or
vibrating
Possible Cause
Corrective Action
Refrigerant overcharge.
Check pressures, charge by subcooling.
Condenser fan motor defective.
Check fan motor.
Condenser coil inlet obstructed or dirty.
Check coil and clearances. Clean coil if necessary.
Air or non-condensables in system.
Check high side equalized pressures, check thermal expansion
valves.
Defective high pressure switch.
Replace.
Restriction in discharge or liquid line.
Check refrigerant line pressures, check thermal expansion
valves, replace any defective component.
Condensing fan relay not pulling in.
Replace.
Low voltage.
Check voltage.
Sustained high discharge pressure.
Check running amperage and conditions described under “low
suction pressure” symptoms.
High suction and discharge pressures.
Check thermal expansion valve setting, check for air in system.
Check air conditions and cfm.
Defective compressor overload.
If compressor is hot, allow compressor to cool for two hours.
Recheck for open circuit.
Improper refrigerant charge.
Check subcooling.
Improperly wired.
Review wiring schematics.
Loose wiring.
Check all connections.
Defective start relay.
Replace relay.
Motor windings damaged.
Verify amp draw.
Improperly wired.
Review wiring schematics.
Low line voltage.
Check voltage.
Loose wiring.
Check all connections.
Defective start relay.
Replace relay.
Motor winding damaged.
Verify amp draws. Replace compressor if necessary.
Internal compressor mechanical damage.
Replace.
Refrigerant overcharge.
Check pressures and subcooling.
Liquid floodback.
Check thermal expansion valve setting. Check for refrigerant
overcharge.
Tubing rattle.
Dampen tubing vibration by taping or clamping. Carefully bend
tubing away from contact where possible.
Scroll compressor rotating in reverse.
(3-phase)
Check high and low side pressures during operation to confirm.
Rewire for opposite rotation.
Damaged compressor.
Replace the compressor.
Improper mounting on unit base.
Check that compressor is properly isolated and mounting bolts
are tight.
Always have a completed Pre-Start-Up Checklist and Start-Up Checklist prior to requesting parts or service
information.
VersiVent Energy Recovery Ventilator 37
Troubleshooting – Refrigeration Circuit
Symptom
High suction
pressure
Possible Cause
Corrective Action
Excessive load on evaporator coil.
Check for high entering wet bulb temperature, check for
excessive air flow.
Compressor is unloaded.
(digital scroll)
Check digital scroll controller signal and solenoid valve.
Expansion valve sensing bulb not secured to
suction line.
Check the thermal expansion valve, ensure bulb is insulated.
Check superheat. If superheat is high, then valve is choking
refrigerant flow.
• Check bulb for contact.
• Adjust valve for superheat ~10°F.
• Replace valve power head or valve.
Thermostatic expansion valve. Overfeeding.
Check bulb location and clamping. Adjust superheat. Replace
expansion valve power head.
Room load too large.
Reduce the load or add more equipment.
Overcharged.
Check pressures and subcooling.
Thermal expansion valve setting.
Check thermal expansion setting and calibrate
superheat / subcooling.
Air inlet to condenser dirty or obstructed.
Check for proper clearances and possible air recirculating.
Clean coil.
Condenser fan motor defective.
Check condenser fan motor.
High discharge Too much refrigerant.
pressure
Non-condensable in system.
Low suction
pressure
Check subcooling. Remove excess refrigerant.
Remove non-condensable from system.
Dirty condenser coil.
Clean condenser coil.
Condenser fan not running or running
backwards.
Check electrical circuit and fuse. Check fan cycling controls.
High load conditions.
Add more equipment or reduce load.
Refrigerant undercharge/loss of refrigerant
charge.
Check pressures and subcooling.
Blower running backward.
Confirm blower rotation. If reversed, interchange any two wires
from 3-phase disconnect.
Low entering air temperature.
(Low load conditions).
Check entering air wet bulb conditions.
Refrigerant leak.
Check system for leaks. Repair leaks and add refrigerant.
Evaporator dirty or iced-up, or airflow
restricted.
Clean the coil. Check fan operation. Check airflow.
Plugged liquid line filter-drier.
Replace filter-drier, check psi across filter.
Improper hot gas bypass setting.
Check setting and correct as required.
Expansion valve defective, superheat too
high or valve too small.
Adjust valve for proper superheat or replace the expansion
valve if too small or defective.
Moisture in system, check sight glass.
Reclaim refrigerant, check for leaks, recharge.
Insufficient refrigerant charge.
Check subcooling, check for leak. Repair leak and add
refrigerant.
Defective or improperly adjusted expansion
Low discharge valve.
pressure
Low suction pressure.
Faulty condenser temperature controls.
(Condensing fan cycle switch).
38 VersiVent Energy Recovery Ventilator
Check superheating and adjust thermal expansion valve.
See “low suction pressure”.
Check condenser controls and reset to obtain desired
condensing temperature.
Troubleshooting – Refrigeration Circuit
Symptom
Compressor
short cycles
Compressor
loses oil
Not enough
cooling or
lack of cooling
Liquid line
is frosted
or wet
Suction line is
frosting
Frost on
evaporator
coil
Possible Cause
Corrective Action
Thermostat location or controls malfunction.
Check thermostat, check heat anticipator setting.
Improper refrigerant charge.
Check subcooling, verify superheat.
Defective low pressure control.
Check high or low pressure switch.
Poor air distribution.
Check ductwork for recirculating.
High discharge pressure.
See “high discharge pressure”.
Low airflow at evaporator(s).
Check blower operation and airstream restrictions.
Incorrect unit selection (oversized).
Contact factory.
Refrigerant leak.
Check system for leaks. Repair leaks and add refrigerant.
Short cycling.
Check low pressure control settings.
Refrigerant flood back.
Check thermal expansion valve setting. Check for refrigerant
overcharge. Check crankcase heater operation.
Reheat flush cycle inadequate.
Contact factory.
Refrigeration undercharged.
Check subcooling. Adjust charge, if necessary.
Dirty filter or evaporator coil.
Check filter, coil and airflow.
Dirty or clogged condenser coil.
Check coil and airflow.
Air or other non-condensables in system.
Check equalized high side pressure with equivalent outdoor
temperature.
Restriction in suction and liquid line.
Check for restrictions in refrigerant circuit.
Control contacts stuck.
Check wiring.
Excessive load.
Add more equipment or reduce room load.
Restriction in liquid line.
Clear restriction upstream of point of frosting.
Insufficient evaporator airflow.
Check airflow, check filters, check VFD control signal for proper
operation.
Malfunctioning or defective expansion valve.
Check bulb of thermal expansion valve.
Hot gas bypass valve not functioning
properly.
Check valve. If defective, replace.
Manual hot gas bypass valve closed.
Open valve.
Low load or airflow.
Increase airflow, check filters.
Always have a completed Pre-Start-Up Checklist and Start-Up Checklist prior to requesting parts or service
information.
Troubleshooting - Energy Wheel
Symptom
Energy wheel
does NOT turn
Energy wheel
runs intermittently
Possible Cause
Corrective Action
Air seals are too tight.
Refer to Adjust the Air Seals found in the Start-Up
Components, Energy Wheel section.
Broken belt.
Replace.
No power to wheel motor.
Make sure wheel drive is plugged in. Verify power is
available.
Wheel motor overloads are tripping due to
rubbing between wheel and air seals.
Recheck air seals, make sure they are not too tight. Refer
to Adjust the Air Seals in the Start-Up Components,
Energy Wheel section.
VersiVent Energy Recovery Ventilator 39
Troubleshooting - Controller Alarms
Troubleshooting - Rotation Sensor
The first step in troubleshooting the unit is to check
the on-board alarm indicators. Several of the electronic
controls in the unit monitor the system for faults and will
go into alarm, shutting down the unit or a single function
within the unit.
When the unit is first turned on, the LED on the back of
the sensor should turn on and stay on with the wheel
running.
Microprocessor Controller
Check the screen on the
microprocessor for an
alarm condition. If it is in
alarm condition, a message
will show on the screen.
The microprocessor controller is located in the main
control center. If it is in alarm condition, the alarm button
will blink red. Press the alarm button to see the specific
condition or to reset the microprocessor. Refer to the
microprocessor controller Installation Operation and
Maintenance manual for detailed information on fault
codes and see the unit-specific wiring diagram.
Phase Monitor
The phase monitor has two LED
indicator lights, one red and one
green. Green indicates proper
operational status, red indicates the
unit has detected a fault and is in
alarm condition.
Variable Frequency Drive (VFD)
VFDs have a display screen that will
show an alarm condition. If a fault such
as a voltage spike occurs, the VFD will
go into alarm and will not reset until a
hard restart is performed. See the unitspecific manufacturer’s manual supplied
with the unit. VFDs are located in the
main control center.
1. When the wheel is spinning, the contact in the
rotation sensor is closed and the small LED light on
the sensor in ON.
2. When the wheel is stopped there is a 10-20 second
delay before the sensor will indicate no rotation.
When the sensor indicates no rotation, it opens the
internal contact and the LED light of OFF.
3. If the LED comes on and then shuts off after 5
seconds or less, the sensor is NOT properly set.
Remove the adjustment plug and turn the adjustment
screw clockwise until a slight stop is felt. Then
turn the adjustment screw out 151⁄2 turns counter
clockwise. The sensor is not properly set, re-install
the adjustment plug.
4. If the LED comes on and then shuts off after 10-20
seconds, the sensor is properly set although it is
either to close to the wheel or not close enough.
It should be 1⁄8 inch from the wheel. Verify that the
sensor depth was set using the appropriate gauge.
When the wheel is unplugged and the unit is still
powered on:
5. The LED should stay on for 10-20 seconds and then
turn off.
Troubleshooting - Digital Scroll
Compressor Controller (PDX Only)
The Fault Code chart is printed on the back of the
controller. Note that if the controller generates either a
Code 2 or a Code 4 Lockout, a manual reset must be
performed. Manual Reset is accomplished by shutting
off main power to the unit and then turning it back on.
FX05 Furnace Controller
Present only if an indirect gas-fired furnace option is
present.
The FX05 furnace controller
will display an alarm condition
if present. The controller
will be found in the furnace
control center. See the furnace
Installation, Operation and
Maintenance manual and the controller manufacturer’s
unit-specific manual for further information.
Digital Compressor Controller Fault Codes
Alert
Code
System
Condition
Diagnostic
Alert Light
Action
Code 2*
High discharge
temp trip
Blinks 2 times
Lockout
Code 3
Compressor
protector trip
Blinks 3 times
Lockout
Code 4*
Locked rotor
Blinks 4 times
Lockout
Code 5
Demand signal
loss
Blinks 5 times
Lockout
Code 6
Discharge
thermistor fault
Blinks 6 times
Reduce
capacity
Code 7
Future
N/A
N/A
Code 8
Welded
contactor
Blinks 8 times
Unload
compressor
Code 9
Low voltage
Blinks 9 times
Trip
compressor
* Protective faults that require manual reset
40 VersiVent Energy Recovery Ventilator
Troubleshooting - Economizer
Alarms
Reference
Addressing Alarms
For technical support contact the Tempered Air
Products group from Monday - Friday, 8AM-5PM CST
at 1-877-202-6123.
Alarms will signify a faulty sensor. When this occurs,
verify all connections to the sensor and controller are
secure. Press enter twice to clear the alarm. If the issue
persists, consult the factory.
Clearing Alarms
Once the alarm has been identified and the cause has
been removed (e.g. replaced faulty sensor), the alarm
can be cleared from the display.
Technical Support
Refer to the following Installation, Operation and
Maintenance Manuals for additional details. All are
available at www.greenheck.com
• Centrifugal Fan
• PVF/PVG Indirect Gas-Fired Heat Modules
• Microprocessor Controller
To clear an alarm, perform the following:
1.
2.
3.
4.
5.
6.
Navigate to the desired alarm.
Press the (enter).
ERASE? displays.
Press (enter).
ALARM ERASED displays.
Press
(escape) to complete the action and return
to the previous menu.
NOTE
If an alarm still exists after you clear it, it redisplays
within 5 seconds.
VersiVent Energy Recovery Ventilator 41
Component Location
3
4
2
1
5
6
12
7
8
9
11
10
1. Supply blower
• Plenum fan
• Adjustable motor mount for belt tensioning
• Adjustable sheaves for speed control
2. Removable energy recovery wheel segments
3. Energy recovery wheel cassette
• One wheel for model VER-45 and VER-65
• Two wheels for model VER-90
4. Optional supply weatherhood with 2 inch
• Aluminum mesh filter
5. Optional Electric Preheat Frost Control
6. Optional supply and exhaust air filter racks for
• 2-inch MERV 8, 30% efficient
7. Optional Final Filters
• 2-inch MERV 8 30% efficient
• 4-inch MERV 11 65% efficient
• 4-inch MERV 13 85% efficient
42 VersiVent Energy Recovery Ventilator
8. Coil section optional equipment.
Not all items depicted above.
• Packaged or split DX cooling coil – DX
• Hot gas reheat coil – HGRH
• Chilled water coil – CW
• Wrap around heat pipe – HP
• Hot water coil – HW
• Electric heat – EH
• Indirect gas furnace – IG; located downstream of
Plenum Supply Fan
9. Vibration isolators (quantity 4 per blower)
• Spring Isolators — Supply Fan
• Neoprene Isolators — Exhaust Fan (not shown)
10. Compressor(s)
11. Condensing coil
12. Condensing fans
Maintenance Log
Date ___________________Time _____________ AM/PM
Date ___________________Time _____________ AM/PM
Notes: ___________________________________________
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Date ___________________Time _____________ AM/PM
Date ___________________Time _____________ AM/PM
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Date ___________________Time _____________ AM/PM
Date ___________________Time _____________ AM/PM
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Date ___________________Time _____________ AM/PM
Date ___________________Time _____________ AM/PM
Notes: ___________________________________________
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Date ___________________Time _____________ AM/PM
Notes: ___________________________________________
Notes: ___________________________________________
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VersiVent Energy Recovery Ventilator 43
Our Commitment
As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications
without notice.
Specific Greenheck product warranties are located on greenheck.com within the product area tabs and in the
Library under Warranties.
Greenheck catalog VersiVent provide additional information
describing the equipment, fan performance, available
accessories, and specification data.
AMCA Publication 410-96, Safety Practices for Users and
Installers of Industrial and Commercial Fans, provides
additional safety information. This publication can be obtained
from AMCA International, Inc. at www.amca.org.
®
Phone: 715.359.6171 • Fax: 715.355.2399 • Parts: 800.355.5354 • E-mail: [email protected] • Website: www.greenheck.com
44 471849 • Model VER IOM, Rev. 3, October 2013
Copyright 2013 © Greenheck Fan Corp.