Accurex XRV-25 Installation, Operation And Maintenance Manual

Document 475597

Model XRV

Packaged Rooftop Ventilator

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!

General Safety Information

Only qualified personnel should install and maintain 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.

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 Electrical 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 wheel faster than maximum cataloged fan RPM. Adjustments to fan speed significantly affect 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. Verify that the power source is compatible with the equipment.

6. Never open access doors to the unit while it is running.

WARNING

The roof lining contains high voltage wiring. To prevent electrocution, do not puncture the interior or exterior panels of the roof.

DANGER

• Always disconnect power before working on or near this equipment. Lock and tag the disconnect switch or breaker to prevent accidental power up.

• If this unit is equipped with optional gas accessories, turn off gas supply whenever power is disconnected.

CAUTION

This unit is equipped with a compressed refrigerant system. If a leak in the system should occur, immediately evacuate the area. An EPA Certified

Technician must be engaged to make repairs or corrections. Refrigerant leaks may also cause bodily harm.

CAUTION

When servicing the unit, the internal components may be hot enough to cause pain or injury. Allow time for cooling before servicing.

Packaged Rooftop Ventilator 1

Table of Contents

General Safety Information . . . . . . . . . . . . . . . . . . . 1

Receiving, Handling, Storage . . . . . . . . . . . . . . . . . 3

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation

Typical Unit Weights and Dimensions . . . . . . . . . . . . . . 6

Service Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Additional Clearances for Packaged DX . . . . . . . . . . . . 7

Handling Concerns for Units with Package DX . . . . . . 7

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Roof Curb Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Optional Piping Vestibule . . . . . . . . . . . . . . . . . . . . . . . 8

Ductwork Configurations . . . . . . . . . . . . . . . . . . . . . . . 8

Rail Mounting and Layout . . . . . . . . . . . . . . . . . . . . . . . 9

Recommended Electrical and

Gas Supply Entry Locations . . . . . . . . . . . . . . . . . . 9

Factory-Installed Refrigeration System

Component s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Start-Up – Unit

Model and Serial Number . . . . . . . . . . . . . . . . . . . . 17

Start-Up – Components

Supply Fan (Plenum Type) . . . . . . . . . . . . . . . . . . . . 22

Fan Wheel Rotation Direction . . . . . . . . . . . . . . . . . 22

Piping Installation

Optional Coil Piping . . . . . . . . . . . . . . . . . . . . . . . . 10

Discharge Air Temperature Sensor . . . . . . . . . . . . . 22

Hot Gas Reheat Valve . . . . . . . . . . . . . . . . . . . . . . . 22

Troubleshooting

Alarms

Microprocessor Controller . . . . . . . . . . . . . . . . . . 22

Phase Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Variable Frequency Drive . . . . . . . . . . . . . . . . . . . 22

Optional Digital Scroll Compressor Controller . . . 22

Electrical Information . . . . . . . . . . . . . . . . . . . . . . . 11

Determine the Size of Main Power Lines . . . . . . . . 11

Determine the Size of Electric Heater Wiring . . . . . 11

Provide the Opening(s) for the Electrical

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Connect the Power Supplies . . . . . . . . . . . . . . . . . 11

Wire the Optional Convenience Outlet . . . . . . . . . . 11

Connect Field-Wired Low Voltage Components . . . 11

Control Center Components

Optional Indirect Gas-Fired Furnace . . . . . . . . . . . . 12

Component Operation

Variable Frequency Drive . . . . . . . . . . . . . . . . . . . . . 13

Supply Fan VFD Sequence . . . . . . . . . . . . . . . . . . . 13

Optional Component Operation

Exhaust Fan VFD Sequence . . . . . . . . . . . . . . . . . . 13

OA and Recirc Air Damper Sequence. . . . . . . . . . . 13

Exhaust Fan Only Power . . . . . . . . . . . . . . . . . . . . . 13

Vapor Tight Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Dirty Filter Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Routine Maintenance

Units with Packaged DX, Semiannually . . . . . . . . . 28

Maintenance Procedures

Fan Wheel and Fasteners . . . . . . . . . . . . . . . . . . . . 29

Reference

Venting Connection Locations . . . . . . . . . . . . . . . . 30

Maintenance Log . . . . . . . . . . . . . . . . . . . . Backcover

Our Commitment . . . . . . . . . . . . . . . . . . . . Backcover

Vapor Tight Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Hot Gas Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . 15

Hot Gas Reheat Valve . . . . . . . . . . . . . . . . . . . . . . . 15

2 Packaged Rooftop Ventilator

Receiving

This product may have been subject to road salt during transit. If so, immediately wash off all visible white reside from all exterior surfaces. Upon receiving the product, check to ensure all line items are accounted for by referencing the delivery receipt or packing list.

Inspect each crate or carton for shipping damage before accepting delivery. Alert the carrier if any damage is detected, do not refuse shipment . The customer shall make notation of damage (or shortage of items) on the delivery receipt and all copies of the bill of lading which should be countersigned by the delivering carrier. If damaged, immediately contact your manufacturer’s representative. Any physical damage to the unit after acceptance is not the responsibility of the manufacturer.

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.

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.

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.

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. Units designed for outdoor applications may be stored outdoors. All accessories must be stored indoors in a clean, dry atmosphere.

Indoor

Maintain temperatures evenly to prevent condensation.

Remove any accumulations of dirt, water, ice, or snow and wipe dry before moving to indoor storage. To avoid condensation, allow cold parts to reach room temperature. 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. Clearance should be provided to permit air circulation and space for inspection.

Outdoor

The unit should be placed on a level surface to prevent water from leaking into the unit. The unit should be elevated so that it is above water and snow levels.

Ensure sufficient support to prevent unit 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

While in storage, inspect units once per month. Keep a record of inspection and maintenance performed.

If moisture or dirt accumulations are found on parts, the source should be located and eliminated. At each inspection, rotate the fan wheel by hand ten to fifteen revolutions to distribute lubricant on motor. If paint deterioration begins, consideration should be given to touch-up or repainting. Units with special coatings may require special techniques for touch-up or repair.

Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur. Immediately remove the original rust preventive coating with petroleum solvent and clean with lint-free cloths. Polish any remaining rust from surface with crocus cloth or fine emery paper and oil. Do not destroy the continuity of the surfaces. Wipe 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, 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.


Product Overview

A horizontally configured High Percentage Outdoor

Air unit designed for installation either indoors or outdoors. Each unit has multiple options for cooling and/or heating. The unit is designed to replace air that is exhausted from the building and also heat and cool, as needed. The air volume produced by the unit is constant, but can be optionally modulated to provide a variable air volume (VAV) and recirculation is also offered as an option.

Cooling

Units have the following cooling options available:

• Chilled water coil

Units with packaged DX are shipped fully charged with refrigerant and are ready for operation upon arrival.

Heating

There are three different optional heat sources that can be ordered for this unit: heat exchangers

• Electric heat with infinitely variable SCR control

• Hot water coil

Airflow Arrangement

The unit is capable of Constant Air Volume (CAV),

Variable Air Volume (VAV), 100% Outdoor Air and have recirculating air options.

Safety Listing

Models are listed per ANSI/UL 1995, Heating and

Cooling Equipment and are ETL Certified.

Models and Capacities

The packaged rooftop ventilator is built on three different platform sizes.

Model

XRV-25

XRV-45

XRV-70

Cooling Capacity

5 to 15 tons

15 to 30 tons

25 to 45 tons


Subassemblies

Blower

Either one or two plenum-type fans. All units are equipped with a plenum fan for Supply Air and a second may be selected for Exhaust (Relief) Air.

Coils

Evaporator coil (optional)

Condenser coil (optional, packaged DX only)

Water coil (optional)

Reheat coil (optional)

Compressors

Each unit having packaged DX will have either one or two refrigerant compressors. Optionally, one of the compressors may be a digital scroll type compressor.

Dampers

Motorized outdoor air damper, motorized recirculating damper. Optional return air damper. Optional gravitytype exhaust damper.

Optional Barometric Relief Damper

Used during economizer mode of the unit when building pressure increases, relief damper will open due to over pressurization.

Electric Heater

An SCR controlled electric heater (not shown) is available on the units. It requires a separate power supply and has its own control panel. See unit-specific wiring diagram.

Filters -

Two-inch thick metal mesh filters in the outdoor weatherhood intake, 2-inch thick pleated paper MERV 8

(standard) or MERV 13 filters in the air stream. Optional

4-inch thick filter bank with a 2-inch thick MERV 8 and

2-inch thick MERV 13 or a 4-inch thick MERV 14 pleated paper supply filters.

Indirect Gas-Fired Furnace -

Furnace model PVG is available on XRV-25 and XRV-45. Model XRV-70 uses furnace model PVF 200-600 or model HMA 700-800.

Packaged DX System -

Any unit may be ordered with a packaged DX system. Housing size XRV-25 will include either one or two compressors; XRV-45 will include two compressors; housing size XRV-70 will include four compressors; a condenser coil(s) and evaporator coil(s) and all required components. Units that have packaged

DX are charged with R410A refrigerant. Do not use tools or parts designed for other refrigerants on these units.

Split DX

The unit may be ordered with a split DX system for connection to a building cooling system.

Vestibule

Some units may be ordered with a factory-assembled vestibule that is to be field-attached to the side of the unit. See lifting instructions.

Open view showing optional condenser coil and fans.

Low Sound Condenser Fans

(optional)

Coils

(optional)

Outdoor Air Filters

Weatherhood Filters

(metal mesh)

Condenser Coils

(optional)

Packaged DX

Compressors

(optional)

Furnace Vest Plate and

Furnace Control Center

(optional)

Main Control

Center

Indirect Gas-Fired Furnace

(optional)

Outdoor Air

Damper

Recirculating

Damper

Plenum-Type

Exhaust Air Blower


Installation

Typical Unit Weights and Dimensions

A

B

1

2

3

W

4

5

6

7

L

H

5

6

7

3

4

1

2

Component Access

Optional Inverter Compressor

Optional Compressor/Electrical

Optional Gas Furnace/Optional Electric Heater

Electrical

Supply Blower

Coil

Filters

Unit

Size

Nominal tonnage

(tons)

Height

(H)

Width

(W)

Length

(L)

Intake

(A)

Condensing

Section

(B)

Nominal weight

(lbs)

Outdoor

Intake

Supply

Discharge

Return

Intake

Exhaust

Discharge

XRV-25

XRV-45

5-15

15-30

59.3

72.5

52.5

68.2

98.6

109

22.1

27.7

30.1

30.1

2,700

4,500 End

Bottom or

Side

Bottom,

End** or

Side*

End+ or

Side*

XRV-70 20-45 90 68 156 22/27^ 30 6,400

All dimensions are shown in inches. Weight is shown in pounds and includes largest supply and exhaust fans, PDX with reheat, largest indirect-gas fired furnace, and all dampers. Actual weights will vary based on the unit configuration.

* Only available with powered exhaust ** Only available without barometric relief

+Only available with barometric relief ^ Above 12,000 cfm

Service Clearances

Clearance

OA End

ACS

CC End

Clearance

NA

ACS = Access

CC = Control Center

NA = Non-Access

OA = Outdoor Air Weatherhood

Unit Size

XRV-25

XRV-45

XRV-70

ACS

40

36

36

CC End OA End

42

58

52

42

42

58

*NA from

Unit

24

24

24

**NA from

CS

18

18

18

All dimensions are shown in inches.

*NA from Unit = no condensing section or piping vestibule

**NA from CS = condensing section

***NA from Vest = piping vestibule

***NA from

Vest

30

30

30


Installation

Additional Clearances for

Packaged DX Units

Packaged DX units require additional clearance because they must have unrestricted air movement around the condenser coil and condenser fans. Hot air is being discharged from the condenser fans during operation. Enough clearance must be provided to avoid recirculation or coil starvation. When equipped with condenser coils, the unit should never be placed under an overhang or inside a building. A minimum of

48 inches above the condenser fans is acceptable, but unobstructed is strongly recommended.

Minimum 48 inches clearance

Condenser Fans

Lifting

1. Before lifting, be sure that all shipping materials have been removed from unit.

2. To assist in determining rigging requirements, weights are provided in the Unit Weights &

Dimensions section of this manual.

3. Unit must be lifted by all lifting lugs provided at top of unit.

4. Spreader bars must span the unit to prevent damage to the cabinet by the lift cables.

WARNING

Spreader bars are required to prevent damage to the cabinet, failure to do so can result in damage that is the installer’s responsibility.

Minimum 18 inches clearance

Condenser Coil

End view of roof top unit with Packaged DX

Handling Concerns for Units with

Packaged DX

Units having packaged DX have a system that is pressurized with refrigerant and if it is damaged, the refrigerant 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.

Before Lifting - Vestibule

Determine whether or not the unit has a vestibule that must be field-attached to the side of the unit. Vestibules are shipped assembled but detached from the unit.

They have lifting lugs on them so they can also be lifted by crane, but the installed location of the unit may make it preferable to install the vestibule on the unit prior to lifting.

Before Lifting - Field Power Access

Determine where high voltage and low voltage wiring is to be brought into the cabinet. If wiring is to be brought into the cabinet through the floor, see Alternate Supply

Entry Locations in this manual. If unit is to be installed on a roof, cut access openings in the roof deck as needed.

5. Always test-lift the unit to check for proper balance and rigging before hoisting to desired location.

6. Never lift unit by weatherhood.

7. Never lift units in windy conditions.

8. Preparation of curb and roof openings should be completed prior to lifting unit to the roof.

9. Check to be sure that gasketing (supplied by others) has been applied to the top of the curb prior to lifting the unit and setting on the curb.

10. Do not use fork lifts for handling unit.


Installation

Roof Curb Mounting

Roof curb details, including duct locations and dimensions, are to be found in the roof curb assembly instructions.

Rooftop units require curbs to be mounted first. The duct connections must be located so they will be clear of structural members of the building.

1. Factory-Supplied Roof Curbs

Roof curbs are Model GKD which are shipped in a knockdown kit (includes duct adapters) and require field assembly (by others). Assembly instructions are included with the curb kit.

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 the curb as required to level.

Install gasketing on top surface of curb (provided by others).

3. Install Ductwork

Installation of all ducts should be done in accordance with SMACNA and AMCA guidelines. Duct adapters are 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 level.

Optional Piping Vestibule

If the unit was ordered with the vestibule, the NA (Non-

Access side) clearance dimension must be measured from the vestibule.

W

L

Typical Unit with Piping Vestibule and

Factory-Supplied Curb Kit

Ductwork Configurations

NOTE

Downblast Discharge Ductwork - whenever downblast discharge is used, the ductwork directly beneath the unit must be connected with either a “T” or an “L” configuration and the area directly beneath the heat source must not have any openings such as louvers or grates.

L

W

Typical Unit with Condensing Section and

Factory-Supplied Curb Kit

5. Install Vestibule

If unit was ordered with a vestibule and it has not yet been attached to the unit, caulk and attach the vestibule at this time.


No louvers or grates

Installation

Rail Mounting and Layout

• The units may be installed on rails provided and installed by others. Ensure that rails are designed to handle the weight of the unit and provide proper load distribution on building supports.

• Make sure that rail positioning does not interfere with the openings on the 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.

Alternate Supply Entry Locations

Each installation is unique and as a result, alternate entry locations may be field-located. Before using any alternate entry location, verify the suitability of the location and ensure the use of an alternate location does not interfere with unit wiring, components or functionality.

WARNING

Never drill holes in the roof of the unit! There is high voltage wiring located between the inner and outer roof panels. Damage to the wiring could cause severe bodily harm or death.

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.

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.

Typical Unit Installed on Rails Supplied by Others

Ground

Joint

Union

Gas to

Controls

Gas Cock

Recommended Electrical and Gas

Supply Entry Locations

Manufacturer recommends that electrical service and gas supply be brought into the cabinet through the end wall, as shown below. There are three penetrations into the cabinet that are required; one for high voltage supply wiring, one for low voltage control wiring and one for either gas supply or high voltage supply wiring for an electric heater.

From Gas Supply

Bleeder Valve or

1/8 in Plugged Tap

8 in. Trap

Typical Gas Supply Piping Connection

Optional Unit

Disconnect

Indirect

Gas

Supply

Location

Field Wiring

Recommended Gas and Electric Supply Entry Locations


Piping Installation

Optional Coil Piping

Factory-installed cooling and heating components are mounted in the coil section of the unit. Note the coil connection locations on the picture. Coil connections are located external to the unit as shown.

Note: DX coil liquid connection is internal to units.

Water coil connections

DX coil liquid connection access door

Water Coils

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. Refer to Drain Trap section.

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, or thermal expansion valve (TXV) with standard models. For further instruction on

DX coil installation and operation contact your compressor and/or condenser manufacturer.

Condensate Drain Trap

This unit is equipped with a stainless steel condensate pan with a stainless steel 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 and to prevent migration of sewer gas back into the unit.

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.

Condensate Overflow Switch

This unit is equipped with an optional factory-mounted condensate overflow switch. In the event that a high level of condensate is detected, a dry contact will be powered (24 VAC). This dry contact can be used for field monitoring of condensate levels. All monitoring and control shall be provided by others.


Electrical Information

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 Electric 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 105ºC, except for an energy cut-off or sensor lead wire which must be rated to 150ºC.

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.

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.

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.

Provide the Opening(s) for the Electrical

Connections

Electrical openings vary by unit size and arrangement and are field-supplied.

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.

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.

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 unit-specific wiring diagram located on the inside of the control center access door.

The low voltage control circuit is 24 VAC and control wiring should not exceed 0.75 ohms.

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.

If wire resistance exceeds 0.75 ohms, an industrialstyle, plug-in relay should be added to the unit control center and wired in place of the remote switch (typically between terminal blocks R and G on the terminal strip.

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

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.


Control Center Components

Main Control Center Components

Image represents a typical XRV installation. Components and locations will vary on housing size and configuration.

High Voltage Side

4

4

HIGH VOLTAGE SIDE

Accessible via control center door supply is terminated here

2. Fuse holders

3. Phase monitor

4. Compressor motor contactors

5. Condensing fan motor contactors

6. Wheel motor contactor

7. Transformer

8. Unit Disconnect

Low Voltage Side

9. Microprocessor controller

10. Monitoring points

11. Low voltage terminal strip

12. Relays

13. Dirty filter switch

14. Outdoor airflow monitor

15. Exhaust airflow monitor

16. Digital scroll controller

10

9

14

15

13

16

3

2 2

8

7

1

11

12

LOW VOLTAGE SIDE

Accessible via compressor door

2

4 5 4 5 6

Optional Indirect Gas-Fired Furnace

Note: In some models, two furnaces are installed to provide greater output. When two furnaces are installed, they are in parallel and both will operate at the same time and the same output. Both furnaces will have identical controls.

7 7

1. Single-stage valve

2. Modulating valve

3. PCOE expansion board

4. Ignition controller

5. Transformer

6. Combustion blower

7. Burner manifold

8. Collector box

3

1

4

2

5

3

1

4

2

5

6

6 8 8

Dual furnaces shown. Available on housing 80 and 120 with furnace capacities 500 MBH or higher.

For further information on the optional furnace and its control center, see the Indirect Gas-Fired Heat lOM shipped with the unit.


Component Operation

Phase Monitor

The unit control circuitry includes a phase monitor that constantly checks for phase reversal, phase imbalance, loss of phase or a power brownout. When it detects a fault, it cuts off the 24 VAC that goes to the low voltage terminal strip, thereby shutting off all motors.

Variable Frequency Drive (VFD)

If a VFD was provided and installed at the factory, it has been pre-set to control the speed of the blower motor for optimum performance. The motor speed needs to be verified during test and balance of the unit.

If the system was configured for Constant Air Volume

(CAV), the VFD will operate in an ON/OFF fashion and the speed of the motor will not change. If the system was configured for Variable Air Volume (VAV), the microprocessor will constantly monitor operating conditions and provide a signal to the VFD, changing the VFD output as needed.

The VFD may alternatively be connected to an external signal such as provided by a BMS and be operated by a

2-10 VDC or a 4-20 mA input.

Supply Fan VFD Sequence

Optional Room CO2 Sensor: The microprocessor will modulate the supply fan based on a comparison of the

CO2 set point to the actual CO2 levels reported from the sensor. Mechanical high static protection cutoffs must be installed by others to protect the system and equipment from over-pressurization.

Optional Duct Static Pressure Sensor: The microprocessor will modulate the supply fan based on a comparison of the duct static pressure set point to the actual duct static pressure level reported from the sensor. Mechanical high static protection cutoffs must be installed by others to protect the system and equipment from over-pressurization. The manufacturer does not assume responsibility for this.

Optional Building Static Pressure Sensor: The supply fan is modulated based upon the signal from a building static pressure sensor. The microprocessor will modulate the supply fan based on a comparison of the building static pressure set point to the actual building static pressure level reported from the sensor.

Optional Single Zone VAV: The microprocessor will use a space mounted temp sensor to vary heating and cooling capacity and the airflow delivered by the fan to maintain room-air temp at a desired set point.

Optional 0-10 VDC by others to VFD: Supply fan is modulated by a 0-10 VDC, field-provided by others.


Exhaust Fan VFD Sequence

Optional Building Static Pressure Sensor: The exhaust fan is modulated based upon the signal from a building static pressure sensor. The microprocessor will modulate the exhaust fan based upon a comparison of the building static pressure level reported from the sensor.

Optional Outdoor Air Damper Tracking: The microprocessor will proportionally modulate the exhaust fan based upon the outdoor air damper position.

Optional Supply Tracking: The microprocessor will proportionally modulate the exhaust fan based upon the supply fan.

Optional 0-10 VDC by Others to VFD: The supply fan is modulated by a 0-10 VDC provided by others in the field.

Outdoor Air and Recirculated (Recirc) Air

Damper Sequence

Optional Room CO2 Sensor: The microprocessor will proportionally modulate the OA/RA dampers based upon a comparison of the CO2 set point to the actual

CO2 level reported from the sensor. As the CO2 level rises, the controller will proportionally modulate the outdoor air damper open, between the minimum and maximum OA position.

Optional Building Pressure: The OA/RA dampers will modulate based upon the signal from a building static pressure sensor. The controller will modulate the dampers, between the minimum and maximum OA positions, based upon a comparison of the building static pressure set point to the actual building static pressure level reported from the sensor.

Exhaust Fan Only Power

The exhaust fan will have a dedicated power circuit where in the case of a power outage, the exhaust fan will still run. A phase monitor will detect an outage or power loss and open the contact, disconnecting all power to the unit and controller. An external signal will need to be sent to a relay to power the exhaust fan, enabling the fan to run at a maximum speed. This sequence is NOT to be used for high temperature exhaust applications.

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.



Electronically Commutated (EC)

Condenser Fans with Standard Scroll or

Digital Scroll Compressors

The EC condenser fan will modulate up and down to maintain the highest liquid line pressure. The factory set points are: Set ( left dial ): 23 barg; Diff ( right dial ): 5 barg.

Fan operation with these set points are as follows.

The fan will be at max speed (~1140 rpm) when the highest liquid line saturation temperature is 118°F (410 psig, 28 barg). The fan remains at

Set (left dial): 23 barg;

Diff (right dial): 5 barg max speed if the pressure is higher than 410 psig (28 barg). The fan will be at min speed (~180 rpm) when the highest liquid line saturation temperature is 105°F (340 psig, 23 barg). Below this pressure, the fan will be off.

The fan modulates linearly between the min and max speeds. If unit is selected with inverter compressor, reference the supplemental Reference Guide for

Microprocessor Controller.

Airflow Monitor

A factory-wired, mounted, and powered airflow monitoring system is provided in the outdoor and/or exhaust air streams. The airflow control system offers the following functionality:

• Display of outdoor and/or exhaust airflow rate in actual cubic feet per minute (CFM) or actual liters per second (LPS) on a 16 character LCD display.

• Two configurable analog outputs for transmitting outdoor and/or exhaust airflow rate, outdoor air temperature, or a proportional-integral-derivative

(PID) control signal based on an outdoor airflow set point.

• A configurable digital output that operates based on an airflow set point or range.

Operation

Outdoor and/or exhaust airflow monitoring is accomplished using two thermal dispersion sensors that accurately measure airflow velocity down to zero feet per minute (fpm). The airflow controller takes the average measurement for two sensor configurations, and determines the outdoor airflow rate based on the effective intake area. Field calibration of the outdoor airflow monitoring device determines the effective intake area of the unit.

For additional information on how to navigate through the airflow controller menus, refer to technical manuals from GreenTrol® Automation Inc. at www.greentrol.com.

IMPORTANT

For the airflow monitoring device to perform as intended, field calibration is required. Calibration of the airflow monitoring device requires an independent measurement of airflow and should be performed when the system undergoes test and balance.



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 Control

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 field-adjustable.

The microprocessor controller can be interfaced with a Building Management System through LonWorks®,

BACnet®, or ModBus.

Please refer to the 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. If equipped with a room temperature and/or relative humidity sensor, the unit can cycle on to maintain unoccupied room set points if there is a call for unoccupied heating, cooling, or dehumidification.

During the unoccupied mode, the supply and exhaust

(if equipped) fans will be off unless there is a call for cooling, heating, or dehumidification in the space.

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.

Hot Gas Reheat Valve

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.

Controls by Others

The reheat coil needs to be purged to ensure adequate oil return. It is recommended that every six hours of reheat compressor run time should initiate a six minute purge cycle. During the purge cycle, the reheat valve should be modulated to 100% open to the reheat coil.


Factory-Installed Refrigeration System Components

Packaged DX Cooling with Three Way Hot Gas Reheat and Hot Gas Bypass

1. Compressor

2. High Limit Pressure Switch

The switch opens when refrigerant pressure increases above the set point in the discharge line.

A manual reset is then required.

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

4. Hot Gas Reheat Coil (Optional)

5. Hot Gas Reheat Check Valve (Optional)

6. Condenser Fans

7. Condensing Coil

8. Liquid Receiver (Optional)

9. Liquid Line Filter Drier

10. Sight Glass

11. Fan Cycle Switch(es)

The switch(es) open or close based on liquid refrigerant pressure to control the condensing fans to maintain liquid pressure.

12. 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 coil access panel.

13. Evaporative Coil

14. Low Limit Pressure Switch

The switch is installed on the suction line and disables the DX system when the suction pressure drops below the set point. The switch will auto reset when the pressure rises above the auto-reset set point.

15. Service Access Ports

16. Hot Gas Bypass Manual Shut Off Valve (Optional)

Used to disable hot gas bypass for service and troubleshooting procedures.

17. Hot Gas Bypass Valve (Optional)

On units equipped with hot gas bypass, hot gas from the compressor is injected into the liquid line of the evaporator coil after the TXV.

Valve - To adjust the valve, 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.

18. Pressure Gauge & Transducer (Optional EC condenser fans only)

See Optional Electronically Commutated (EC)

Condenser Fans under the component operation.


Start-Up Unit

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 birdscreens 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 40ºF.

• Do not short-cycle the compressor. Allow

5 minutes between “on” cycles to prevent compressor damage.

• DX system is charged with refrigerant. Start-up must be performed by EPA Certified Technician.

WARNING

Prior to starting up the unit, power must be energized for 24 hours without a call for cool to allow the compressor crankcase heaters time to boil off any liquid refrigerant present in the compressor.

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. ___________________________________

Unit Serial No. ____________________________________

Compressor 1 Model No. __________________________




Start-Up Date ____________________________________

Start-Up Personnel Name __________________________

Start-Up Company ________________________________

Phone Number ___________________________________


Start-Up Unit

Pre-Start-Up Checklist

Remove any foreign objects that are located in the unit.

Check all fasteners, set-screws, and locking collars on the fans, bearings, drives, motor bases and accessories for tightness.

Rotate the fan wheels by hand and ensure no parts are rubbing.

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 factory wiring connections.

Verify proper drain trap installation.

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 all coils within the unit. Fins may get damaged in transit or during construction. Carefully straighten fins with a fin comb.

Electrical

Disconnect and lock-out all power switches.

Verify control wire gauge.

All field-mounted sensors and instruments are installed and wired.

Unit controls are off.

Electrical service matches unit voltage.

Electrical field wiring is complete.

All electrical connections are tightened.

Compressor and motor breakers or fuses are open

(disabled).

Main power is wired to the disconnect.

Discharge air sensor is installed per wiring instructions.

Space temperature and humidity sensors are installed per if selected with unit.

Compressors

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.

Compressor shipping brackets are removed if provided.

IG Furnace

If there is an indirect gas-fired furnace in this unit, refer to the manual provided with this unit for Pre-

Start-Up information.

Gas piping is complete and gas lines are purged.

Gas venting is in place.

Hot Water/Chilled Water Coils

Chilled water piping system is complete.

Hot water piping system is complete.

Control valves are installed, wired, and operating properly.

Water coils are balanced to design GPM.

Water system is free of air.

SPECIAL TOOLS REQUIRED

• Voltage Meter (with wire probes)

• Amperage Meter

• Pressure Gauges – (refrigerant)

• Tachometer

• Thermometer

• Incline 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.

Make sure Pre-Start-Up checklist is complete.

Jumper R to G, R to Y1, and R to Y2 (if applicable) on the control board.

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 1-2 minutes.

Voltage Imbalance

In a 3-phase system, excessive voltage imbalance between phases will cause motors to overheat and eventually fail. Maximum allowable imbalance is 2%.

To determine voltage imbalance, use recorded voltage measurements in this formula.

Key: V1, V2, V3 = line voltages as measured

VA (average) = (V1 + V2 + V3) / 3

VD = Line voltage (V1, V2 or V3) that deviates farthest from average (VA)

Formula: % Voltage Imbalance = [100 x (VA-VD)] /VA


Start-Up Checklist

Line Voltage. Check at unit disconnect.

L1-L2

Motor Amp Draw

Supply Motor 1 Amps

Supply Motor 2 Amps

L1

L1

Exhaust Motor 1 Amps L1

Exhaust Motor 2 Amps L1

Fan RPM

Supply Fan RPM

Exhaust Fan RPM

Condensing Fans

Condensing Fan 1

Condensing Fan 2

Condensing Fan 3

Condensing Fan 4

L1

L1

L1

L1

Compressors

Outdoor Air Temperature

Return Air Temperature

L1

L2

L3

Crankcase Heater

Superheat

Should be between 7º and 9ºF

Subcooling

Should be between 10º and 12ºF

Discharge Pressure

Should be between 300 and 500 PSIG

Suction Line Pressure

Should be between 100 and 135 PSIG

Liquid Line Temp.

Suction Line Temp.

Moisture Indicating Sight Glass

Liquid Visible

Color of Center Dot

Hot Gas Bypass Operational

Volts L2-L3 Volts L1-L3

Amps

Amps

Amps

Amps

L2

L2

L2

L2

Amps

Amps

Amps

Amps

Correct fan rotation direction?

Supply Fan

Exhaust Fan

Yes / No

Yes / No

L3

L3

L3

L3

Amps

Amps

Amps

Amps

L2

L2

L2

L2

Amps

Amps

Amps

Amps

L3

L3

L3

L3

Amps

Amps

Amps

Amps

Deg F

Deg F

Outdoor Air Relative Humidity

Return Air Relative Humidity

% RH

% RH

Compressor 1 Compressor 2 Compressor 3 Compressor 4

Amps Amps Amps Amps

Amps

Amps

Amps

Amps

Amps

Amps

Amps

Amps

Amps

Amps

Amps

Amps

Deg. F Deg. F Deg. F Deg. F

Deg. F

PSIG

PSIG

Deg. F

Deg. F

Deg. F

PSIG

PSIG

Deg. F

Deg. F

Deg. F

PSIG

PSIG

Deg. F

Deg. F

Deg. F

PSIG

PSIG

Deg. F

Deg. F

Yes / No

Purple / Pink

Yes / No

Yes / No

Purple / Pink

NA

Yes / No

Purple / Pink

NA

Yes / No

Purple / Pink

NA

Volts

Amps

Amps

Amps

Amps


Start-Up Components

Fan

The fan should be checked for free rotation. If any binding occurs, check for concealed damage and foreign objects in the fan housing.

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.

Supply Fan (Plenum Type)

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

Wheel be as shown; there is a smooth feel to the

Offset

Inlet

Cone profile when moving one component to the other.

Fan Size

ER35C

ER45C

ER50C

ER56C

Offset

(inches)

5/32

3/16

13/64

1/4

Tolerance

(inches)

± 1/32

± 1/32

± 1/32

± 1/32

Refer to the respective Installation, Operation and

Maintenance Manual shipped with this unit for additional start-up and maintenance information regarding the plenum fan.

Fan Wheel Rotation Direction

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 the bearings. Refer to the Troubleshooting portion of this manual if a problem develops.

Supply/Exhaust Fan

The optional exhaust fan is a direct-drive plenum type.

Fan speed is controlled by a VFD which, in turn, is controlled by the microprocessor controller or by an external signal. Motor speed will be set on the VFD during the unit Test and Balance, but after that, the

VFD will not normally be changed. Always check the motor amperage rating shown on the motor nameplate when changing the fan RPM. All access doors must be installed except the control center door.

Vibration

Vibration Causes

Off axis or loose components

Drive component unbalance

Poor inlet / outlet conditions

Foundation stiffness

Excessive vibration may be experienced during initial start-up. Left unchecked, excessive vibration can cause a multitude of problems, including structural and/or component failure. The most common sources of vibration are listed.

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.

Generally, fan vibration and noise is transmitted to other parts of the building by the ductwork. To eliminate this undesirable effect, the use of flexible connectors is recommended.

Discharge Air Temperature Sensor

Units are supplied with a Discharge Air Temperature

Sensor that is to be field-installed prior to unit startup. The sensor is to be installed at least three duct diameters downstream of the heat exchanger.

The sensor must be connected directly to the microprocessor controller. All other sensors and low voltage devices are to be connected to the low voltage terminal strip in the control center.

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.

Typical Discharge Air

Temperature Sensor

Optional 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.


Start-Up Components

Airflow Monitor

For additional information on how to navigate through the airflow controller menus, refer to technical manuals

GF-2200A from GreenTrol® Automation Inc. at www.greentrol.com.

Field calibration procedure:

1. Turn off power to the unit using the power disconnect(s).

2. Remove the cover from the GreenTrol airflow monitoring controller.

3. Install a jumper wire between terminals R and G on the unit’s terminal board if one isn’t present.

4. When safe, turn the power back on to the unit using the power disconnect(s).

If no microprocessor controller, skip to step 8.

Steps 5 thru 7 are for microprocessor only.

5. Look at the unit’s microprocessor controller screen and view the status of the unit. If the displayed status is “System Off” continue with step 6, otherwise go to step 7.

6. Adjust the unit on/off priorities on the unit’s microprocessor controller so that the unit will run for calibration.

a. Push the “Prg” button on the microprocessor controller.

b. Use the up and down arrows to get to the “On/

Off Unit” menu.

c. Push the enter button to view the current unit on/off priorities. d. Push the down arrow to display the Unit ON/

OFF Control screen.

e. Record the settings below so they can be changed back when calibration is complete.

By digit input: ___________

By ___________

By ___________ f. Use the enter button to navigate between the different settings on the page, use the up and down arrows to change the values so that “By digit input” is the only setting with “Yes”.

7. Enter the service override menu to control the damper position.

a. At the Home Screen push the “Prg” button. (If you’re not at the home screen push the escape button until you get there).

b. Use the up and down arrows to get to the

“Service” menu, then push the enter button.

c. If you’re asked for a password, enter “1000” for the password and push enter.

d. Use the up and down arrows to get to the

“Overrides” screen, then push enter.

e. Use the arrow buttons to get the supply override.

8. Measure the supply airflow rate of the unit using an approved test and balance method.

9. Without making any changes to the system, calibrate the airflow monitoring controller so it reads the airflow measured in step 8 by using the

Field Calibration Wizard.

a. The field calibration lasts for two minutes. Any significant changes in airflow will affect the accuracy of the reading.

b. To enter the Field Calibration Wizard, hold the

Down and Enter buttons simultaneously on the airflow controller, then release the buttons.

c. Push the enter button to go to Wizard 1.

d. Push the enter button twice and change Wiz1

Enable to YES.

e. When asked for the number of calibration points (Cal Points), set the value to 1.

f. Push the enter button when the display says

“Set Flow 1”.

g. After completing the steps above, set the

FLOW1 value to the airflow measured in step 8, then push the enter button to begin calibration.

10. After the calibration is completed, measure the supply airflow rate again and compare with the value on the airflow controller’s display device has been successfully calibrated.

repeat the field calibration process.

11. If you had to change the On/Off priorities on the microprocessor unit controller, change them back to the values that were written down in part 6.

12. Turn off power to the unit using the power disconnect(s) and wait one minute for the variable frequency drive(s) to lose backup power.

13. Replace the cover to the GreenTrol airflow monitoring station.

14. If you added a jumper between terminals R and

G in step 3 remove it at this time. If a jumper was already in place, leave it in place.

15. When safe, turn the power back on to the unit using the power disconnect(s).

a. Recycling of the power resets the manual override values that were set during the calibration.


Troubleshooting – Alarms

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.

Microprocessor Controller

Check the screen on the microprocessor for an alarm condition. If the microprocessor is in an alarm condition, a message will show on the microprocessor controller screen.

The microprocessor is located in the main control center. If the microprocessor 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 IOM for detailed information on fault codes and see the unitspecific 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. The alarm LED will blink to show the specific fault and there is a chart printed on the monitor that shows the code for the blinking light. The phase monitor is self-resetting once the alarm condition is corrected. It is located in the main control center.

Variable Frequency Drive (VFD)

Variable frequency drives 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.

Optional Digital Scroll Compressor

Controller

Present only if packaged DX with digital scroll option is selected. The controller has three LED indicator lights.

One is green, indicating that it has power, one is an alarm indicator that will flash a code for various alarm conditions and the third indicates whether the compressor is operating in a loaded or unloaded condition. See the manufacturer’s unit-specific manual for further information.

See the Fault Code chart below. The Fault Code chart is also 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.

Alert Code

Code 2*

Code 3

Code 4*

Code 5

Code 6

Code 7

Code 8

Digital Scroll Compressor

Controller Fault Codes

System

Condition

High Discharge

Temperature Trip

Compressor

Protector Trip

Locked Rotor

Demand Signal

Loss

Discharge

Thermistor Fault

Future

Welded

Contactor

Diagnostic

Alert Light

Blinks 2 Times

Blinks 3 Times

Blinks 4 Times

Blinks 5 Times

Blinks 6 Times

N/A

Blinks 8 Times

Action

Lockout

Lockout

Lockout

Lockout

Reduce

Capacity

N/A

Unload

Compressor

Code 9 Low Voltage Blinks 9 Times Trip Compressor

*Protective faults that require manual reset.


Troubleshooting – Unit

Symptom Possible Cause

Blower fails to operate

Motor starters

“chatter” or do not pull in

Motor over amps

Low airflow

(cfm)

High airflow

(cfm)

Excessive noise or vibration

Corrective Action

Blown fuse or open circuit breaker.

Defective motor or capacitor.

Motor overloaded.

Electrical.

Control power (24 VAC) wiring run is too long. (Resistance should not exceed 0.75 ohms).

Motor horsepower too low.

Shorted windings in motor.

Unit damper not fully open.

Replace fuse or reset circuit breaker and check amps.

Replace.

Reset VFD and check amps.

Check for On/Off switches. Check for correct supply voltage. Check Control wiring.

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.

See specifications and catalog for fan curves to determine if horsepower is sufficient.

Replace motor.

Adjust damper linkage or replace damper motor.

System static pressure too high.

Blower speed too low.

Fan wheels are operating backwards.

Dirty filter.

Improve ductwork to eliminate losses using good duct practices.

Check maximum motor RPM and compare with catalog data. Verify that external control wiring is in place if required.

For 3-phase, see Direction of Fan Wheel Rotation

Direction in Start-Up, Components section.

Replace filters or follow cleaning procedures in Routine

Maintenance section of this manual.

Repair.

Leaks in ductwork.

Elbows or other obstructions may be obstructing fan outlet.

Correct or improve ductwork.

Blower fan speed too high.

Filter(s) not in place.

Insufficient static pressure (Ps).

(airflow resistance)

Check for correct maximum fan RPM. Decrease maximum fan speed if necessary in the VFD.

Install filters.

Induce Ps into system ductwork. Make sure grilles and access doors are installed. Decrease fan speed if necessary.

Fan wheel rubbing on inlet.

Bearings.

Loose wheel on shaft.

Motor base or blower loose.

Noise being transmitted by duct.

Adjust wheel and/or inlet cone. Tighten wheel hub or bearing collars on shaft.

Replace defective bearing(s). Lubricate bearings. Tighten collars and fasteners.

Tighten wheel hub.

Tighten mounting bolts.

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.

Always have a completed Pre-Start-Up Checklist and Start-Up Checklist prior to requesting parts or service information.


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 controller 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.


Open disconnect switch or circuit breaker.


Close switch and/or breaker.

Compressor contactor not closing.

Blown fuse or tripped breaker.

Low line voltage.

Compressor will not run or does not start

Compressor motor protector open.

Compressor defective.

High pressure switch open or defective.

Check voltage to contactor coil, transformer, slave relay, system. Replace parts as necessary.

Check for reason and repair. Replace fuse after correcting problem.

Check line voltage. If more than 10% from compressor marking, correcting is necessary.

Motor thermal protector automatically resets. Allow time

(2 hours) for compressor to cool down so protector will reset. Restart and check for reason overheat occurred.

Check motor for open circuit, short circuit, grounded windings, or burn out. Compressor may be seized; check refrigerant. If necessary, replace compressor.

If manual reset (high pressure), reset switch. (Switch opens at 610 psi and will not reset above 420 psi for

R-410A). Replace if defective.

Low pressure switch open or defective.

Open room thermostat or control.

(No cooling required).

Loose wiring.

See switch label for set point.

Compressor starts but cuts out on low pressure

Low or loss of refrigerant charge.

Airflow restricted.

Low pressure switch activates at

50 PSIG

Restriction in refrigerant line.

Defective low pressure switch.

Check room temperature. If temperature is proper, wait for thermostat to close.

Check all wire terminals and tighten as necessary.

Check refrigerant pressures and temperatures

(subcooling.)

Check for dirty evaporator coil, dirty filters, dampers closed, iced evaporator coil, improper belt, check motor amps, check duct design.

Check refrigerant pressures, look for frosted tubing and components indicating a restriction. Check pressure drop across the filter drier.

Replace.

24




Symptom Possible Cause Corrective Action

Refrigerant overcharge.

Check pressures, charge by subcooling.

Compressor starts but cuts out on high pressure switch

Condenser fan motor defective.

Condenser coil inlet obstructed or dirty.

Air or non-condensables in system.

Defective high pressure switch.

High pressure activates at

600 PSIG

Restriction in discharge or liquid line.

Condensing fan relay not pulling in.

Check fan motor.

Check coil and clearances. Clean coil if necessary.

Check high side equalized pressures, check thermal expansion valves.

Replace.

Check refrigerant line pressures, check thermal expansion valves, replace any defective component.

Replace.

Low voltage.

Sustained high discharge pressure.

High suction and discharge pressures.

Compressor cuts out on thermal overload

Defective compressor overload.

Improper refrigerant charge.

Improperly wired.

Loose wiring.

Defective start relay.

Motor windings damaged.

Improperly wired.

Low line voltage.

Compressor hums, but will not start

Loose wiring.

Defective start relay.

Motor winding damaged.

Internal compressor mechanical damage.

Refrigerant overcharge.

Check voltage.

Check running amperage and conditions described under

“low suction pressure” symptoms.

Check thermal expansion valve setting, check for air in system. Check air conditions and cfm.

If compressor is hot, allow compressor to cool for two hours. Recheck for open circuit.

Check subcooling.

Review wiring schematics.

Check all connections.

Replace relay.

Verify amp draw.

Review wiring schematics.

Check voltage.

Check all connections.

Replace relay.

Verify amp draws. Replace compressor if necessary.

Replace.

Liquid floodback.

Compressor noisy or vibrating

Tubing rattle.

Scroll compressor rotating in reverse.

(3-phase)

Damaged compressor.

Improper mounting on unit base.

Check pressures and subcooling.

Check thermal expansion valve setting. Check for refrigerant overcharge.

Dampen tubing vibration by taping or clamping. Carefully bend tubing away from contact where possible.

Check high and low side pressures during operation to confirm. Rewire for opposite rotation.

Replace the compressor.

Check that compressor is properly isolated and mounting bolts are tight.





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.

High suction pressure

High discharge pressure

Low suction pressure

Expansion valve sensing bulb not secured to suction line.

Thermostatic expansion valve.

Overfeeding.

Room load too large.

Overcharged.

Thermal expansion valve setting.

Air inlet to condenser dirty or obstructed.

Condenser fan motor defective.

Too much refrigerant.

Non-condensable in system.

Dirty condenser coil.

Condenser fan not running or running backwards.

High load conditions.

Refrigerant undercharge/loss of refrigerant charge.

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.

Check bulb location and clamping. Adjust superheat.

Replace expansion valve power head.

Reduce the load or add more equipment.


Check thermal expansion setting and calibrate superheat / subcooling.

Check for proper clearances and possible air recirculating. Clean coil.

Check condenser fan motor.

Check subcooling. Remove excess refrigerant.

Remove non-condensable from system.

Clean condenser coil.

Check electrical circuit and fuse. Check fan cycling controls.

Add more equipment or reduce load.


Blower running backward.

Confirm blower rotation. If reversed, interchange any two wires from 3-phase disconnect.

Low entering air temperature.

(Low load conditions).

Refrigerant leak.

Evaporator dirty or iced-up, or airflow restricted.

Check entering air wet bulb conditions.

Check system for leaks. Repair leaks and add refrigerant.

Clean the coil. Check fan operation. Check airflow.

Plugged liquid line filter-drier.

Improper hot gas bypass setting.

Replace filter-drier, check psi across filter.

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.

26





Low discharge pressure

Compressor short cycles

Insufficient refrigerant charge.


Check subcooling, check for leak. Repair leak and add refrigerant.

Defective or improperly adjusted expansion valve.

Low suction pressure.

Faulty condenser temperature controls.

(Condensing fan cycle switch).

Thermostat location or controls malfunction.

Check superheating and adjust thermal expansion valve.

See “low suction pressure”.

Check condenser controls and reset to obtain desired condensing temperature.

Check thermostat, check heat anticipator setting.

Improper refrigerant charge.

Check subcooling, verify superheat.

Defective high or low pressure control.

Check high or low pressure switch.

Poor air distribution.

Check ductwork for recirculating.

High discharge pressure.

Low airflow at evaporator(s).

Incorrect unit selection (oversized).

Refrigerant leak.

Short cycling.

Compressor loses oil

Not enough cooling or lack of cooling

Refrigerant flood back.

Reheat flush cycle inadequate.

Refrigeration undercharged.

Dirty filter or evaporator coil.

Dirty or clogged condenser coil.

Air or other non-condensables in system.

Restriction in suction and liquid line.

Control contacts stuck.

Excessive load.

See “high discharge pressure”.

Check blower operation and airstream restrictions.

Contact factory.

Check system for leaks. Repair leaks and add refrigerant.

Check low pressure control settings.

Check thermal expansion valve setting. Check for refrigerant overcharge. Check crankcase heater operation.

Contact factory.

Check subcooling. Adjust charge, if necessary.

Check filter, coil and airflow.

Check coil and airflow.

Check equalized high side pressure with equivalent outdoor temperature.

Check for restrictions in refrigerant circuit.

Check wiring.

Add more equipment or reduce room load.

Liquid line is frosted or wet

Restriction in liquid line.

Clear restriction upstream of point of frosting.

Suction line is frosting

Insufficient evaporator airflow.

Check airflow, check filters, check VFD control signal for proper operation.

Frost on evaporator coil

Malfunctioning or defective expansion valve.

Hot gas bypass valve not functioning properly.

Manual hot gas bypass valve closed.

Low load or airflow.

Check bulb of thermal expansion valve.

Check valve. If defective, replace.

Open valve.

Increase airflow, check filters.



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:

Maintenance Frequency:

Monthly

1. External Filter

Clean metal mesh filters

2. Internal Filters

Replace MERV 8 filters monthly.

Adjust replacement schedule for MERV 13 and

MERV 14 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

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 Procedures:

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 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 wash-down 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.

Internal Filter Maintenance

- 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. Filter must be pleated design with integral metal grid. Two acceptable filter replacements are Aerostat Series 400 or Farr 30/30®.

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.

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.

External Filter Maintenance

- 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

Filter cleaned by rinsing with a mild detergent in warm water prior to start-up.

Outdoor Air Intake Hood

Mesh Filter Access

Coil Maintenance

- 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. High pressure water

(700 psi or less) may be used to clean coils with a fin thickness over 0.0095 inches thick. TEST THE SPRAY

PRESSURE over a small corner of the coil to determine if the fins will withstand the spray pressure.

For coils with fragile fins or high fin density, foaming chemical sprays and washes are available. Many coil cleaners use harsh chemicals, so they must be used with caution by qualified personnel only. Care must be taken not to damage the coils, including the fins, while cleaning. Caution: Fin edges are sharp!

WARNING

Biological hazard. May cause disease. Cleaning should be performed by qualified personnel.

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. Cleaning should be performed by qualified personnel.


Reference - Venting Connection Locations

200-300MBH

COMPRESSOR / CONTROL CENTER

ACCESS

B

A

IG FURNACE

ACCESS

COMBUSTION AIR INLET

EXHAUST OUTLET


EXHAUST OUTLET

B

A

C

D

500MBH

100-150MBH

COMPRESSOR / CONTROL CENTER

ACCESS

C

D

300-400MBH

IG FURNACE

ACCESS

COMPRESSOR

ACCESS

CONTROL CENTER

ACCESS

COMPRESSOR

ACCESS

CONTROL CENTER

ACCESS


EXHAUST OUTLET

B

A

IG FURNACE

ACCESS

B

A

IG FURNACE

ACCESS

C

D

C

D


EXHAUST OUTLET

Model

Furnace

Size (MBH)

XRV-25

XRV-45

100

150

200

250

300

300

400

500

A

14

15.2

14.8

14.9

B

23.5

23.7

23.3

23.6

IG Venting Location

C

20.5

31.5

38.1

25.2

D

20.5

35.9

44.1

57.1

Flue Connection Size

(diameter in inches)

Standard 2-Pipe/Concentric

Exhaust

4

4

Exhaust

4

4

Intake

4

4

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6


Reference - Rated Airflow

AHRI Rating Conditions

Model

XRV-45-15S-*

XRV-45-17.5I-*

XRV-45-17.5D-*

XRV-45-17.5S-*

XRV-45-20I-*

XRV-45-20D-*

XRV-45-20S-*

XRV-45-25I-*

XRV-45-25D-*

XRV-45-25S-*

XRV-45-30I-*

XRV-45-30D-*

XRV-45-30S-*

XRV-70-25D-*

XRV-70-25S-*

XRV-70-30D-*

XRV-70-30S-*

XRV-70-35D-*

XRV-70-35S-*

XRV-70-43D-*

XRV-70-43S-*

XRV-25-5I-*

XRV-25-5D-*

XRV-25-5S-*

XRV-25-7.5I-*

XRV-25-7.5D-*

XRV-25-7.5S-*

XRV-25-10I-*

XRV-25-10D-*

XRV-25-10S-*

XRV-25-12.5I-*

XRV-25-12.5D-*

XRV-25-12.5S-*

XRV-25-15I-*

XRV-25-15D-*

XRV-25-15S-*

XRV-45-15I-*

XRV-45-15D-*

Airflow (SCFM)

5750

5750

5750

6500

6500

7400

7400

7600

7600

8100

8100

4100

4650

4650

4650

5300

5300

5300

5750

5750

5750

2900

2900

3400

3550

3550

3775

3775

3775

4100

4100

2325

2325

2325

2300

2300

2300

2700


Maintenance Log

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

As a result of our commitment to continuous improvement, Accurex reserves the right to change specifications without notice.

Product warranties can be found online at accurex.com, either on the specific product page or in the Warranty section of the website at Accurex.com/Resources/Warranty.

P.O. Box 410 Schofield, WI 54476

Phone: 800.333.1400 • Fax: 715.241.6191

Parts: 800.355.5354 • accurex.com

32 476370 • Grease Trap, Rev. 2, February 2013

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