1. business and industrial
2. energy
3. natural gas

Aston-built Products
Custom-built Dedicated Outdoor Air Systems
Installation, Operation and Maintenance Instructions Manual
Capacities: 1,000 to 300,000+ cfm
Model: EnergyPack®, ERV5000–10000 (indoor/
outdoor), HRV3000–10000 (indoor/outdoor)
©2008 Venmar CES Inc.
Table of Contents
Nomenclature.......................................................................................................................................................................3
Safety Considerations..........................................................................................................................................................8
General Information............................................................................................................................................................8
Recommended Spare Parts............................................................................................................................................8
Unit Inspection on Arrival.............................................................................................................................................9
Unit Application Limitations.........................................................................................................................................9
Installation............................................................................................................................................................................9
Unit Location Requirements..........................................................................................................................................9
Roofcurbs Supplied by Venmar CES (External Applications Only)............................................................................10
Roofcurbs Supplied by Others.....................................................................................................................................10
Rigging, Lifting and Assembling.................................................................................................................................11
Hood Installation.........................................................................................................................................................17
Indoor Suspended Installation....................................................................................................................................17
Field Fabricated Ductwork..........................................................................................................................................18
Electrical Connections..................................................................................................................................................19
Coil, WSHP or Humidifier Piping Connections...........................................................................................................20
Condensate Drain Trap and Lines...............................................................................................................................21
Gas Connections...........................................................................................................................................................21
Refrigerant Systems.....................................................................................................................................................21
Start-up...............................................................................................................................................................................21
Pre Start-up Check.......................................................................................................................................................21
Start-up Procedure.......................................................................................................................................................23
Airflow Balancing........................................................................................................................................................24
Maintenance.......................................................................................................................................................................25
Long-term Storage Maintenance Procedures.............................................................................................................25
Maintenance Summary Chart......................................................................................................................................25
Energy Recovery Wheel...............................................................................................................................................25
Flat Plate Heat/Enthalpy Exchangers..........................................................................................................................29
Heat Pipe Heat Exchangers.........................................................................................................................................29
Refrigerant Systems.....................................................................................................................................................30
Dampers........................................................................................................................................................................31
Belt Driven Fans...........................................................................................................................................................32
FANWALL® Array..........................................................................................................................................................34
Motors..........................................................................................................................................................................39
Filters............................................................................................................................................................................39
Coils...............................................................................................................................................................................39
Controls........................................................................................................................................................................40
Troubleshooting...........................................................................................................................................................40
Appendix A: Roofcurb Generic Assembly Instructions.....................................................................................................41
Appendix B: Water Source Heat Pump (WSHP) Piping, Installation, Maintenance and Troubleshooting...................42
Appendix C: Positive and Negative Pressure Trapping....................................................................................................47
Appendix D: Gas-fired Furnace Modules Installation and Maintenance........................................................................48
Tubular Gas-fired Duct Furnace Module....................................................................................................................48
IG Series Drum and Tube Gas-fired Duct Furnace Module........................................................................................62
Appendix E: EnergyPack®, ERV5000–10000(i/e) and HRV3000–10000(i/e) Start-up Form and Checklist......................82
Appendix F: HEPA Filter Installation.................................................................................................................................90
Appendix G: Electric Heating Coil and Controls Information.........................................................................................92
Appendix H: Extended Dormant Unit Maintenance Procedure......................................................................................94
Appendix I: EnergyPack®, ERV5000–10000 and HRV3000–10000 Maintenance Summary Chart..................................97
Appendix J: Measuring and Adjusting V-belt Tension....................................................................................................98
Appendix K: Energy Recovery Wheel Multi-link Drive Belt Instructions........................................................................99
Appendix L: Fan Bearing Lubrication Schedule..............................................................................................................100
Appendix M: FANWALL® Inlet Cone Alignment............................................................................................................101
Appendix N: Filter Resistance and Latches.....................................................................................................................102
Appendix O: Troubleshooting.........................................................................................................................................103
Appendix P: Adjusting Refrigerant Charge....................................................................................................................105
Manufacturer reserves the right to discontinue or change specifications or designs without notice or obligation.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
2
Nomenclature
EnergyPack® Nomenclature (1,000–300,000+ cfm)
1
2
3
4
5
1. TYPE OF HEAT OR ENERGY RECOVERY DEVICE
W – Wheel - total enthalpy
Ws – Wheel - sensible only
P – Plate - sensible only
(polypropylene or aluminum)
Pe – Plate - enthalpy (HM core)
Pa – Plate - AlphaFlowSM configuration, sensible only
H – Heat pipe heat exchanger
U – U-shaped heat pipe
A – No energy recovery device
(make-up or air handling units)
2. NUMBER OF AIRSTREAMS
3. SUPPLY CFM
Rounded to the nearest thousand
4. INDICATES UNIT INSTALLATION
e – Unit installed outdoors
i – Unit installed indoors
5. TYPE OF SUPPLY FAN/
TYPE OF EXHAUST FAN
F – DWDI forward curved fan
B – DWDI backward inclined, or flat blade
P – SWSI plenum fan (backward inclined airfoil)
W – FANWALL TECHNOLOGY®
P – No fan
6. TYPE OF HEATING
HW – Hot water coil
SC – Steam coil
yTxxxx – Gas-fired serpentine heaters
(y = # of furnace sections; xxxx = heating capacity)
yRxxxx – Indirect gas-fired duct heaters
(y = # of furnace sections; xxxx = heating capacity)
ECxxx – Electric duct heater (xxx = heating capacity)
HG – Hot gas reheat coil (condensing unit supplied by others)
HGxxxx – Hot gas reheat coil (condensing unit supplied by Venmar CES;
xxxx = heating capacity)
IGxxxx – Indirect gas-fired heaters (xxxx = input heating capacity)
DGxxxx – Direct fired gas burner (xxxx = input heating capacity)
X – No heating
6
7
8
9
9. EXTERIOR FINISH
P – Painted finish (standard for exterior units)
C – Corrosion resistant paint
G – Galvanized metal - unpainted
(standard for interior units)
8. TYPE OF HEATING/COOLING
HWCW – Hydronic coil for hot water in heating
season and chilled water in cooling season
HPxxxy – Dx coil with heat pump
(xxx = cooling capacity;
y = # of scroll compressors)
RL – Runaround loop
X – No heating/cooling
7. TYPE OF COOLING
CW – Chilled water coil
Dx – Dx coil (condensing unit supplied
by others)
CSxxxy – Dx coil with air cooled condensing unit
(xxx = cooling capacity;
y = # of scroll compressors)
CTxxxy – Dx coil with air cooled condensing unit
(xxx = cooling capacity;
y = # of scroll compressors in tandem)
Cxxxy – Dx coil with air cooled condensing unit
(xxx = cooling capacity;
y = # of semi-hermetic compressors)
EV – Evaporative cooling section
X – No cooling
©Venmar CES Inc. 2008. All rights reserved throughout the world.
Illustrations cover the general appearance of Venmar CES products at the time of publication and Venmar CES reserves the
right to make changes in design and construction at any time without notice.
™® The following are trademarks or registered trademarks of their respective companies: EnergyPack from Venmar CES Inc.
and FANWALL from Huntair, Inc.
CES Group, LLC d/b/a Venmar CES furnishes equipment pursuant to its then-current Terms and Conditions of Sale and Limited Warranty, copies of which can be found under the Terms & Conditions of Sale and Warranty link at www.ces-group.com.
Extended warranties, if any, shall be as offered and acknowledged in writing by Venmar CES.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
3
ERV5000–ERV10000 Indoor Nomenclature (4,000–10,000)
1
2
3
4
5
6
7
8
1. FROST CONTROL
D – Recirc defrost1
E – Exhaust only2
V – VSD frost prevention
N – Non-defrost3
2. VOLTAGE/SPEED
B – 208 VAC/1/60 – one-speed8/10*
C – 230 VAC/1/60 – one-speed8/10*
D – 208 VAC/3/60 – one-speed
E – 230 VAC/3/60 – one-speed
F – 460 VAC/3/60 – one-speed
G – 575 VAC/3/60 – one-speed
N – 208 VAC/3/60 – VFD4
O – 230 VAC/3/60 – VFD4
P – 460 VAC/3/60 – VFD4
Q – 575 VAC/3/60 – VFD4/5
3. SENSOR CONTACTS
D – Dirty filter contacts
W – Wheel rotation sensor
B – Dirty filter contacts and
wheel rotation sensor
X – No contacts, no sensor
4. EXTERNAL FINISH
S – Standard galvanized package
G – Grey enamel paint finish
C – Corrosion resistant exterior paint finish
5. OUTSIDE AIR DAMPER
1 – Non-insulated spring return (low leak)
2 – Insulated spring return (low leak)
3 – No damper
6. EXHAUST AIR DAMPER
1 – Non-insulated spring return (low leak)
2 – Insulated spring return (low leak)
3 – No damper
7. EXTERNAL DISCONNECT
F – Fused disconnect switch7
N – Non-fused disconnect switch7
X – No disconnect switch
8. OUTSIDE AIR INTAKE
E – End outside air intake
T – Top outside air intake
S – Side outside air intake
B – Bottom outside air intake
9. EXHAUST DISCHARGE
E – End exhaust discharge
T – Top exhaust discharge
D – Down exhaust discharge
10. SUPPLY DISCHARGE
E – End supply discharge
T – Top supply discharge
D – Down supply discharge
11. RETURN AIR
E – End return air
T – Top return air
B – Bottom return air
9
10
11
12
13
14 15
16
17
18
19
19. COIL ARRANGEMENT
H – Heating, cooling, access section
C – Cooling, heating, access section
S – Heating, cooling, no access section
X – No access section
(one coil or no coils)
18. COOLING
C – Chilled water (5 row)
W – Chilled water (6 row)
D – Dx cooling (5 row, 1 circuit)
F – Dx cooling (6 row, 2 circuits)
X – No cooling
17. HEATING
ERV5000i–10000i
H – Hot water (1 row)
J – Hot water (2 row)
S – Steam heat (1 row)
G – Hot gas re-heat (2 row)
X – No heat
ERV5000i
D – Electric heat (25 kW)8/9
E – Electric heat (43 kW)8/9
F – Electric heat (78 kW)8/9
ERV6500i
D – Electric heat (35 kW)8/9
E – Electric heat (55 kW)8/9
F – Electric heat (100 kW)8/9
ERV8000i
D – Electric heat (42 kW)8/9
E – Electric heat (71 kW)8/9
F – Electric heat (128 kW)8/9
ERV10000i
D – Electric heat (54 kW)8/9
E – Electric heat (91 kW)8/9
F – Electric heat (164 kW)8/9
16. PURGE SECTION
P – Purge section
X – No purge section
15. BLOWER ISOLATION
R – Rubber in shear pads isolation
S – Spring blower isolation
14. FREE COOLING
E – Free cooling (enthalpy controller)
D – Free cooling (dry bulb)
X – No free cooling
13. HEF FILTRATION
H – High efficiency supply filter
(4” 80–85% MERV 14)6
X – No HEF filtration
12. MEF FILTRATION
S – MEF supply filter6
E – MEF exhaust filter
B – MEF supply and exhaust filters
X – No MEF filtration
Note:
1 When ordering frost control, you must order outside air and exhaust air dampers. VFD motors are not available with this frost control option.
2 Outside air damper recommended. VFD motors are not available with this frost control option.
3 No dampers required.
4 All VFD options include one controller per motor.
5 All VFD options for 575 VAC/3/60 include a line reactor.
6 You must order an MEF supply filter when ordering HEF supply filtration.
7 Fused/non-fused disconnect is factory installed.
8 Electric heat is not available with single-phase motor options.
9 Electric heat to be used in re-heat position only (not for frost control).
10 15 hp motor is not available with this voltage option (*ERV10000i only).
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
4
ERV5000–ERV10000 Outdoor Nomenclature (4,000–10,000)
1
2
3
4
5
6
7
8
1. FROST CONTROL
D – Recirc defrost1
E – Exhaust only2
V – VSD frost prevention
N – Non-defrost3
2. VOLTAGE/SPEED
B – 208 VAC/1/60 – one-speed9/11*
C – 230 VAC/1/60 – one-speed9/11*
D – 208 VAC/3/60 – one-speed
E – 230 VAC/3/60 – one-speed
F – 460 VAC/3/60 – one-speed
G – 575 VAC/3/60 – one-speed
N – 208 VAC/3/60 – VFD5
O – 230 VAC/3/60 – VFD5
P – 460 VAC/3/60 – VFD5
Q – 575 VAC/3/60 – VFD5/6
3. SENSOR CONTACTS
D – Dirty filter contacts
W – Wheel rotation sensor
B – Dirty filter contacts and
wheel rotation sensor
X – No contacts, no sensor
4. EXTERNAL FINISH
S – Standard galvanized package
G – Grey enamel paint finish
C – Corrosion resistant exterior paint finish
5. OUTSIDE AIR DAMPER
1 – Non-insulated spring return (low leak)
2 – Insulated spring return (low leak)
3 – No damper
6. EXHAUST AIR DAMPER
1 – Non-insulated spring return (low leak)
2 – Insulated spring return (low leak)
3 – Gravity backdraft damper (low leak)
4 – No damper
9
10
11
12
13
14 15
16
17
18
19
19. ROOFCURB
R – Insulated roofcurb
X – No roofcurb
18. COIL ARRANGEMENT
H – Heating, cooling, access section
C – Cooling, heating, access section
S – Heating, cooling, no access section
X – No access section
(one coil or no coils)
17. COOLING
C – Chilled water (5 row)
W – Chilled water (6 row)
D – Dx cooling (5 row, 1 circuit)
F – Dx cooling (6 row, 2 circuits)
X – No cooling
16. HEATING
ERV5000e–10000e
H – Hot water (1 row)
J – Hot water (2 row)
S – Steam heat (1 row)
G – Hot gas re-heat (2 row)
X – No heat
ERV5000e
D – Electric heat (25 kW)9/10
E – Electric heat (43 kW)9/10
F – Electric heat (78 kW)9/10
ERV6500e
D – Electric heat (35 kW)9/10
E – Electric heat (55 kW)9/10
F – Electric heat (100 kW)9/10
ERV8000e
D – Electric heat (42 kW)9/10
E – Electric heat (71 kW)9/10
F – Electric heat (128 kW)9/10
7. EXTERNAL DISCONNECT
F – Fused disconnect switch8
N – Non-fused disconnect switch8
X – No disconnect switch
8. HOODS
H – Intake/exhaust hoods
X – No hoods4
9. SUPPLY DISCHARGE
D – Down supply discharge
E – End supply discharge
ERV10000e
10. RETURN AIR
B – Bottom return air
E – End return air
11. MEF FILTRATION
S – MEF supply filter7
E – MEF exhaust filter
B – MEF supply and exhaust filters
X – No MEF filtration
13. FREE COOLING
E – Free cooling (enthalpy controller)
D – Free cooling (dry bulb)
X – No free cooling
D – Electric heat (54 kW)9/10
E – Electric heat (91 kW)9/10
F – Electric heat (164 kW)9/10
15. PURGE SECTION
P – Purge section
X – No purge section
14. BLOWER ISOLATION
R – Rubber in shear pads isolation
S – Spring blower isolation
12. HEF FILTRATION
H – High efficiency supply filter
(4” 80–85% MERV 14)7
X – No HEF filtration
Note:
1 When ordering frost control, you must order outside air and exhaust air dampers. VFD motors are not available with this frost control option.
2 Outside air damper recommended. VFD motors are not available with this frost control option.
3 No dampers required.
4 Must order hoods when ordering dampers.
5 All VFD options include one controller per motor.
6 All VFD options for 575 VAC/3/60 include a line reactor.
7 You must order an MEF supply filter when ordering HEF supply filtration.
8 Fused/non-fused disconnect is factory installed.
9 Electric heat is not available with single-phase motor options.
10 Electric heat to be used in reheat position only (not for frost control).
11 15 hp motor is not available with the voltage option (*ERV10000e only).
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
5
HRV3000–HRV10000 Indoor Nomenclature (2,500–11,500 cfm)
1
2
3
4
5
6
7
8
9
1. FROST CONTROL
D – Recirc defrost1/4
E – Exhaust only2/4
F – Face and bypass3
T – Traversing defrost4
N – Non-defrost5
2. VOLTAGE/SPEED
B – 208 VAC/1/60 – one-speed6/7*
C – 230 VAC/1/60 – one-speed6/7*
D – 208 VAC/3/60 – one-speed
E – 230 VAC/3/60 – one-speed
F – 460 VAC/3/60 – one-speed
G – 575 VAC/3/60 – one-speed
N – 208 VAC/3/60 – VFD8
O – 230 VAC/3/60 – VFD8
P – 460 VAC/3/60 – VFD8
Q – 575 VAC/3/60 – VFD8/9
3. ENERGY RECOVERY
P – Poly core10
A – Aluminum core
H – HM core11
4. INTERNAL PROTECTION
1 – 2” insulation, double wall
2 – Corrosion resistant interior (heresite)
3 – Pool application package12/13/14
5. SENSOR CONTACTS
D – Dirty filter contacts
X – No contacts
6. EXTERNAL FINISH
S – Standard galvanized package
G – Grey enamel paint finish
C – Corrosion resistant exterior
7. OUTSIDE AIR DAMPER
1 – Non-insulated spring return (low leak)
2 – Insulated spring return (low leak)
3 – No damper
8. EXHAUST AIR DAMPER
1 – Non-insulated spring return (low leak)
2 – Insulated spring return (low leak)
3 – No damper
9. EXTERNAL DISCONNECT
F – Fused disconnect switch15
N – Non-fused disconnect switch15
X – No disconnect switch
10. OUTSIDE AIR INTAKE
E – End outside air intake
T – Top outside air intake
11. EXHAUST DISCHARGE
E – End exhaust discharge
T – Top exhaust discharge
Note:
1 When ordering frost control, you must order outside air and exhaust
air dampers.
2 Outside air damper recommended.
3 And/or free cooling (c/w dampers and actuator).
4 VFD motors are not available with this frost control option.
5 No dampers required. Non-defrost is only available if the outside air
temperature is greater than 10ºF [−17ºC].
6 Electric heat is not available with single-phase motor options.
7 15 hp motor is not available with this voltage option. (*HRV10000i only)
8 All VFD options include one controller per motor.
9 This option includes a line reactor.
10 Traversing defrost may not be suitable under all thermal conditions with a
polypropylene heat exchanger. Consult the factory.
11 Traversing defrost is not available with the HM core option.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
10
11
12
13
14 15
16
17
18
18. COIL ARRANGEMENT
H – Heating, cooling, access section
C – Cooling, heating, access section
S – Heating, cooling, no access section
X – No access section (one coil or no coils)
17. COOLING
C – Chilled water (5 row)
W – Chilled water (6 row)
D – Dx cooling (5 row, 1 circuit)
F – Dx cooling (6 row, 2 circuits)
X – No cooling
16. HEATING
HRV3000i–10000i
H – Hot water (1 row)
S – Steam heat (1 row)
J – Hot water (2 row)
X – No heat
HRV3000i
D – Electric heat (15 kW)6/16
E – Electric heat (27 kW)6/16
F – Electric heat (49 kW)6/16
HRV5000i
D – Electric heat (25 kW)6/16
E – Electric heat (43 kW)6/16
F – Electric heat (78 kW)6/16
HRV6500i
D – Electric heat (35 kW)6/16
E – Electric heat (55 kW)6/16
F – Electric heat (100 kW)6/16
HRV8000i
D – Electric heat (42 kW)6/16
E – Electric heat (71 kW)6/16
F – Electric heat (128 kW)6/16
HRV10000i
D – Electric heat (54 kW)6/16
E – Electric heat (91 kW)6/16
F – Electric heat (164 kW)6/16
15. BLOWER ISOLATION
R – Rubber in shear pads isolation
S – Spring blower isolation
14. FILTRATION
S – Standard filtration
(2” 25–30% MERV 8)
H – High efficiency filtration
(4” 80–85% MERV 14)
13. RETURN AIR
E – End return air
B – Bottom return air
12. SUPPLY DISCHARGE
E – End supply discharge
D – Down supply discharge
12 The ‘Pool application package’ requires the following nomenclature options
also be selected: ‘F – Face and bypass’ (Frost Control), ‘P – Poly core’ (Energy
Recovery), ‘2 – Insulated spring return (low leak)’ (Outside Air Damper) and
‘2 – Insulated spring return (low leak)’ (Exhaust Air Damper).
13 The ‘Pool application package’ includes: corrosion resistant (heresite) internal
unit protection, epoxy coating on the exhaust air fan, TEFC exhaust air fan
motor, liquid tight conduit on all high voltage wiring, urethane insulation
throughout (including insulated middle partition), condensate drain pan at
exhaust air leaving station.
14 It is recommended that supply and return dampers be installed in the ductwork.
These dampers shall close when the unit is not in operation.
15 Fused/non-fused disconnect switch is factory installed.
16 Electric heat to be used in re-heat position only (not for frost control).
6
HRV3000–HRV10000 Outdoor Nomenclature (2,500–11,500 cfm)
1
2
3
4
5
6
7
8
9
10
1. FROST CONTROL
D – Recirc defrost1/4
E – Exhaust only2/4
F – Face and bypass3
T – Traversing defrost4
N – Non-defrost5
2. VOLTAGE/SPEED
B – 208 VAC/1/60 – one-speed6/7*
C – 230 VAC/1/60 – one-speed6/7*
D – 208 VAC/3/60 – one-speed
E – 230 VAC/3/60 – one-speed
F – 460 VAC/3/60 – one-speed
G – 575 VAC/3/60 – one-speed
N – 208 VAC/3/60 – VFD8
O – 230 VAC/3/60 – VFD8
P – 460 VAC/3/60 – VFD8
Q – 575 VAC/3/60 – VFD8/9
3. ENERGY RECOVERY
P – Poly core10
A – Aluminum core
H – HM core11
4. INTERNAL PROTECTION
1 – 2” insulation, double wall
2 – Corrosion resistant interior (heresite)
3 – Pool application package12/13/14
5. SENSOR CONTACTS
D – Dirty filter contacts
X – No contacts
6. EXTERNAL FINISH
S – Standard galvanized package
G – Grey enamel paint finish
C – Corrosion resistant exterior
7. OUTSIDE AIR DAMPER
1 – Non-insulated spring return (low leak)
2 – Insulated spring return (low leak)
3 – No damper
8. EXHAUST AIR DAMPER
1 – Non-insulated spring return (low leak)
2 – Insulated spring return (low leak)
3 – No damper
9. EXTERNAL DISCONNECT
F – Fused disconnect switch15
N – Non-fused disconnect switch15
X – No disconnect switch
10. HOODS
H – Intake/exhaust hoods
X – No hoods
11. SUPPLY DISCHARGE
E – End supply discharge
D – Down supply discharge
Note:
1 When ordering frost control, you must order outside air and exhaust
air dampers.
2 Outside air damper recommended.
3 And/or free cooling (c/w dampers and actuator).
4 VFD motors are not available with this frost control option.
5 No dampers required. Non-defrost is only available if the outside air
temperature is greater than 10ºF [−17ºC].
6 Electric heat is not available with single-phase motor options.
7 15 hp motor is not available with this voltage option. (*HRV10000i only.)
8 All VFD options include one controller per motor.
9 This option includes a line reactor.
10 Traversing defrost may not be suitable under all thermal conditions with a
polypropylene heat exchanger. Consult the factory.
11 Traversing defrost is not available with the HM core option.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
11
12
13
14 15
16
17
18
18. ROOFCURB
R – Insulated roofcurb
X – No roofcurb
17. COIL ARRANGEMENT
H – Heating, cooling, access section
C – Cooling, heating, access section
S – Heating, cooling, no access section
X – No access section (one coil or no coils)
16. COOLING
C – Chilled water (5 row)
W – Chilled water (6 row)
D – Dx cooling (5 row, 1 circuit)
F – Dx cooling (6 row, 2 circuits)
X - No cooling
15. HEATING
HRV3000e–10000e
H – Hot water (1 row)
S – Steam heat (1 row)
J – Hot water (2 row)
X – No heat
HRV3000e
D – Electric heat (15 kW)6/16
E – Electric heat (27 kW)6/16
F – Electric heat (49 kW)6/16
HRV5000e
D – Electric heat (25 kW)6/16
E – Electric heat (43 kW)6/16
F – Electric heat (78 kW)6/16
HRV6500e
D – Electric heat (35 kW)6/16
E – Electric heat (55 kW)6/16
F – Electric heat (100 kW)6/16
HRV8000e
D – Electric heat (42 kW)6/16
E – Electric heat (71 kW)6/16
F – Electric heat (128 kW)6/16
HRV10000e
D – Electric heat (54 kW)6/16
E – Electric heat (91 kW)6/16
F – Electric heat (164 kW)6/16
14. BLOWER ISOLATION
R – Rubber in shear pads isolation
S – Spring blower isolation
13. FILTRATION
S – Standard filtration
(2” 25–30% MERV 8)
H – High efficiency filtration
(4” 80–85% MERV 14)
12. RETURN AIR
E – End return air
B – Bottom return air
12 The ‘Pool application package’ requires the following nomenclature options
also be selected: ‘F – Face and bypass’ (Frost Control), ‘P – Poly core’ (Energy
Recovery), ‘2 – Insulated spring return (low leak)’ (Outside Air Damper) and
‘2 – Insulated spring return (low leak)’ (Exhaust Air Damper).
13 The ‘Pool application package’ includes: corrosion resistant (heresite) internal
unit protection, epoxy coating on the exhaust air fan, TEFC exhaust air fan
motor, liquid tight conduit on all high voltage wiring, urethane insulation
throughout (including insulated middle partition), condensate drain pan at
exhaust air leaving station.
14 It is recommended that supply and return dampers be installed in the ductwork.
These dampers shall close when the unit is not in operation.
15 Fused/non-fused disconnect switch is factory installed.
16 Electric heat to be used in re-heat position only (not for frost control).
7
Safety Considerations
Warning, Caution and Important notes appear throughout
this manual in specific and appropriate locations to alert
Installation Contractors, Maintenance or Service Personnel
of potential safety hazards, possible equipment damage or
to alert personnel of special procedures or instructions that
must be followed as outlined below.
!
WARNING
Identifies an instruction which, if not followed, might cause
serious personal injuries including possibility of death.
CAUTION
Hazards may exist within this equipment because it contains electrical and powerful moving components. Only
qualified service personnel should install or service this
equipment. Untrained personnel can perform basic maintenance such as maintaining filters. Observe precautions
marked in literature and on labels attached to the unit.
Follow all safety codes.
!
WARNING
Disconnect the main power switch to the unit before performing service or maintenance. Electric shock can cause
personal injury or death.
Identifies an instruction which, if not followed, might severely damage the unit, its components, the assembly or
final installation.
IMPORTANT
Indicates supplementary information needed to fully
complete an instruction or installation.
General Information
This manual is designed to provide general information
on the common operation of all standard and optional
components that may have been installed in the unit. Note
that some sections of this manual may not apply to your
unit. This manual has been designed for a general purpose
and describes all options offered by Venmar CES that
could be included in the unit. Consult the manual from
the component manufacturer if more detailed technical
information about a specific component is required.
All documentation that was specifically designed for your
unit has been included in the pocket of the control panel,
including (and if applicable):
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•
•
•
•
Mechanical drawings
Unit nomenclature
Electrical schematics
Sequence of control
Variable Frequency Drive (VFD) manual and CD
(when supplied)
• DDC controller documentation (when supplied)
User’s manual
Communication protocol documentation
Keypad documentation
Recommended Spare Parts
Spare parts should be ordered at the time the installation is accepted by the owner. Spare parts will reduce
the down time in the event of a failure. The list of spare
parts outlined below is considered minimal. Installation in
remote locations or when the operation of heating equipment is essential may require more spare parts than listed.
Please contact the service department at Venmar CES for
recommendations.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Minimum spare parts include:
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•
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•
Two sets of fuses
One matching set of fan belts
One set of filters
One burner control relay module, flame signal amplifier and purge card (optional)
One flame sensor (optional)
One spark igniter (optional)
8
Unit Inspection on Arrival
Inspect the equipment exterior and interior for any damage that may have occurred during unit shipment and for
shipped loose parts. Ensure there is no damage to any
protruding exterior components such as door handles,
disconnect switch handle, etc. or to internal components
such as fans, motors, heat exchanger, dampers and drains.
File a claim with the shipping company if the unit is damaged. Check the packing slip against all items received. If
any items are missing sign the carrier’s bill of landing with
the notation “Shipment Received Less Item #_____.” Contact the factory immediately if damage is found. No return
shipment will be accepted without authorization.
Unit Application Limitations
CAUTION
Venmar CES equipment is not designed to be used for
temporary heating, cooling and/or ventilation during
construction.
Using Venmar CES units for temporary ventilation during construction is subject to the unit warranty terms and
should be reviewed carefully before proceeding, as this
may void the standard warranty conditions.
Fine dust, larger particulate matter, solvents, varnishes and
other chemicals may cause filter clogging and elevated
cabinet pressures, higher power consumption and possible
irreparable damage to the desiccant material of the energy
recovery device, which could reduce energy recovery performance and also reduce the heat transfer effectiveness
of other components. Potential damages include, but are
not limited to, these examples.
Installation
Unit Location Requirements
Consult local building codes and electrical codes for special installation requirements and note additional requirements listed in this manual. In choosing the installation
location of the unit, consider the following factors:
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The unit should be installed to allow easy access for
maintenance and for systems operation.
Clearance around the unit should be a minimum of
39” [1,000 mm] and 48” [1,219 mm] around the
condenser section to allow easy access for maintenance and for system operation. For clearances to
remove component, consult factory.
Locate the unit in an area requiring the least amount
of ductwork and direction changes to allow optimum
performance, to reduce pressure loss and to use less
electricity to achieve proper ventilation. Ductwork
must be in accordance with ducting mechanical rules
to prevent sound issues and system effects.
The fresh air intake hood must be positioned away
from sources of contamination such as other HVAC
unit exhaust outlets or vents, hot chimneys or kitchen
exhaust vents.
Fresh air intake must also be positioned in a direction
opposite to that of prevailing winds and clear of any
obstruction to prevent turbulence buildup to reduce
entry of snow or rain.
The unit should be mounted on a level foundation
to allow condensation to flow into internal drains.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
•
•
The foundation must provide adequate continuous
support to the full perimeter of the base and all cross
members requiring support to minimize deflection of
the unit base frame to not more than 1/16” [1.6 mm]
over the entire length and width. In addition to these
recommendations, a Structural Engineer must be involved to properly size supporting structural elements.
When mounting the unit indoors, if drain connections are required, mount the unit on a housekeeping pad of sufficient height to allow for drain trap
height and condensate lines to slope toward the
building drain, install condensate pumps to reduce
height of housekeeping pads or drill holes in the concrete pad or mechanical room floor for sufficient trap
height.
When mounting the unit on a roofcurb check the
height from the finished roof to the bottom of the
intake hood. Consult with local authorities or your
building code for minimal intake hood height for the
water-tight height from and above the finished roof,
and in snow prone areas, the buildup of snow, to determine the height of the roofcurb. Venmar CES optional roofcurbs measure 18” [457 mm] in height. If
additional height is required from the finished roof to
the top of the roofcurb, to the bottom of the intake
hood or if other than level, custom height roofcurbs
must be ordered.
9
Roofcurbs Supplied by Venmar CES (External Applications Only)
Roofcurbs supplied by Venmar CES should be mounted as
follows:
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The roofcurb is shipped knocked-down with assembly hardware and instructions provided. The roofcurb
must be field erected, assembled and set in place by
the Installing Contractor (see Appendix A).
Roofcurb dimensions are submitted with the unit
mechanical drawings which can also be found in the
unit control panel pocket or by calling Technical Support personnel from the Venmar CES factory.
The cross members must be positioned as per the
roofcurb drawing to properly support the unit.
The building structure must provide continuous structural support under the full perimeter of the roofcurb
and under all cross members.
After the roofcurb has been assembled, ensure that
the curb dimensions suit the unit for which it is designated and also ensure that the structural supports
for the roofcurb are correct.
Ensure that the assembled curb is square, plumb and
level to within 1/16” [1.6 mm] over the entire length.
The roofcurb must be shimmed to the building structure as required to provide continuous support under
its full perimeter and under all its cross members.
The roofcurb must be fastened to the building structure.
•
•
IMPORTANT
The following items must be completed prior to setting
the unit on the roofcurb.
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Continuous ½”
bead ADBOND 1465
acoustical butyl sealant
The Installing Contractor is responsible for making
the curb water-tight by caulking all roofcurb joints.
See Appendix A for assembly instructions for standard design curbs or with optional wood nailer.
The roofcurb roofing must be completed including
insulation, cant strip, flashing and counter-flashing.
Vertical ductwork supplied by Sheet Metal Contractor must be attached to the roofcurb cross members
and building structure, not to the unit. See Field
Fabricated Ductwork for suggested ductwork attachment.
If there is no building roof access underneath the
unit, and drain or piping connections must be made
(in the roofing), it is recommended to do so before
unit installation using the appropriate materials provided by the Installing Contractor.
Use the ADBOND 1465 acoustical butyl sealant supplied with the unit and apply a continuous ½” [13
mm] bead to the top perimeter of the roofcurb for a
positive air and water-tight seal and to ease section
movement when pulling modules together (if applicable). The ADBOND 1465 acoustical butyl sealant
remains indefinitely pliable and sticky and should
only be applied just prior to unit installation to avoid
smudging.
Use the ½” x 1½” [13 x 38 mm] polyvinyl gasket
with adhesive strip supplied with the unit and apply
it on top of the perimeter of the duct opening connections.
IMPORTANT
Figure 1: Continuous ½” [13 mm] bead of ADBOND 1465
acoustical butyl sealant or equivalent applied to top perimeter of roofcurb and ½” x 1½” [13 x 38 mm] gasket with
adhesive strip applied to the bottom duct opening connections just prior to unit installation.
The ADBOND 1465 acoustical butyl sealant between the
unit and the roofcurb is critical for a positive air and watertight seal. If improperly applied this can result in air and
water leakage and poor unit performance (see Figure 1).
Roofcurbs Supplied by Others
Roofcurbs supplied by others must be designed with the
same dimensions, cross member arrangement and location as per Venmar CES roofcurb drawings and must be
designed to evenly withstand perimeter and cross section
static loads.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
IMPORTANT
Venmar CES is not liable for any damages, costs or other
issues arising from roofcurbs supplied by others.
10
Rigging, Lifting and Assembling
•
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•
IMPORTANT
Carefully read all the instructions contained herein.
Before proceeding with any work, correlate these
instructions with the information provided on the
curb and equipment shop drawing for the specific
project.
These instructions outline the suggested method of
rigging, lifting and installing a Venmar CES unit. All
local codes and fire regulations must be verified and
adhered to by the Installing Contractor.
Before assembling, hoisting or setting any pieces of
the supporting curbs or units, verify that the proper
unit is being directed to the correct location, as designated by the architectural and engineering design
drawings.
Safety first: ensure that all safety practices recommended by local safety associations are continuously in use.
If any questions arise during the installation procedure, please contact the factory.
The Installing Contractor is responsible for the unit
being air and water-tight at the joints between sections and between the roofcurb and the unit.
All holes that have been made by the Installing or
Electrical Contractor after receiving and installing
the unit must be well sealed to prevent air and/or
water infiltration.
supplied by Venmar CES and located inside one (or more)
of the unit sections, where this (yellow) label, as shown
below, is applied on the door.
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For Single Section Units
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Lifting crane of the appropriate capacity
Adjustable spreader bars
Cables (cables, chains or straps)
Curb flashing (when required—based on roofing
construction)
All tools required to pull the sections together
(chains, chain blocks, chain type come alongs, etc.)
All construction equipment and labor required to
complete the work according to local codes
Condensate and/or P-trap piping hardware
All tools and materials required for level unit installation
½” [13 mm] wood shims required to set the gap between the unit base frame and the curb
Installation and Assembly Materials
All materials for sealing the unit to the top of a factory
supplied roofcurb, for assembling a multi-sectional unit
as detailed below and per the instructions that follow are
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
ADBOND 1465 acoustical butyl sealant or equivalent
(applied to top perimeter of curb just prior to unit
installation).
Polyvinyl gasket with adhesive strip (½” x 1½” [13 x
38 mm] x required length) applied on duct opening
connections.
For Multi-section (Modular) Units
•
Rigging, Lifting and Assembling Equipment
All rigging equipment and labor (as applicable) is provided
by the Installing Contractor as detailed below. It is highly
recommended that extra quantities of all items listed be
on hand. The rigging procedure and/or equipment used to
lift the unit may differ depending on the physical dimensions of the unit, its location, the jobsite, the Installing
Contractor and Crane Operator preferences.
IMPORTANT
Installation and assembly materials are in this section.
Before setting unit on a roofcurb or structural support, read and follow the Rigging, Lifting and Assembling Instructions in the Installation, Operation
and Maintenance Instructions Manual.
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ADBOND 1465 acoustical butyl sealant or equivalent
(applied to top perimeter of curb or to the top perimeter joint of a horizontally split indoor unit lower
section just prior to unit installation). The use of
ADBOND 1465 acoustical butyl sealant or equivalent
is required to create a proper seal to minimize the
risk of water infiltration and ease section movement
when pulling modules together. Do not use the
butyl sealer on the exterior split section joints as it
remains pliable, sticky and should it become smeared
is difficult to clean.
Polyvinyl gasket with adhesive strip (½” x 1½” [13 x
38 mm] x required length) applied between unit sections (for split section joints and duct opening connections).
3/8” x 4” Grade 5 full thread zinc plated bolts, with
two washers and one nut each (to secure sections
together).
Adseal 1800 series (from Adchem Adhesives) clear
silicone based sealant or equivalent (for side joint and
top joint).
Roof seam ends made of metal with applied gasket.
Roof joint caps x required length.
Self-drilling 5/16 hex head #12-14 x 1” zinc plated
screws with rubber washer (for roof caps).
Rigging, Lifting and Assembling Instructions
Depending on size, the unit or unit sections of a multisection (modular) unit will arrive at the jobsite on a standard flatbed or special low bed trailer. Each unit or unit
section is identified with labels, as per the mechanical
drawings. At ground level, ensure that any crating used
for shipping purposes is removed if there is a possibility
that it will interfere with the placing or assembling of the
unit or unit sections on the roofcurb, structural steel or
housekeeping pad.
11
IMPORTANT
Adjustable
spreader bars (typ.)
For multi-section (modular) units, make certain to always
rig, lift and install an end section with bottom duct connection first.
Pulleys (typ.)
Unit or unit sections shall be lifted by cables attached to all
the lifting lugs. Consult the mechanical drawings located
in the pocket of the control panel for the number of lifting lugs, number of sections and unit weight. For multisection (modular) unit check for additional lugs located
between split sections. Lifting lugs are factory bolted to
the unit or unit section base.
Detail A
Use clevis and
clevis pin to attach
cable to lifting lugs.
See Detail A
CAUTION
All lifting lugs provided must be used when rigging units
or unit sections. Rigging and lifting unit or unit sections
without using all lifting lugs provided will compromise
the structural integrity of the unit or unit section. Never
lift, rig or ceiling suspend from the top of the unit or unit
sections. Using a forklift or similar device for moving, lifting or rigging unit or unit sections is prohibited.
When lifting the unit or unit sections, use adjustable
spreader bars, pulleys, cables (straps or chains) in order
to properly distribute the load, applying an even vertical
lifting force only at all the lifting lugs to prevent structural
damage to the unit or unit section or prevent cables from
rubbing against the cabinet (see Figure 2). Provide additional blocking and coverings (as required) to prevent
damage to the unit finish and/or components. The adjustable spreader bars are required to maintain a clearance
between the cables and the unit or unit section of at least
12” [305 mm] beyond the sides. Venmar CES will not be
responsible for any damage caused to the unit casing during the lifting process. Main areas where damage may
occur are: electrical panels, filter gauges, rain gutters,
hoods, roofing corners, door handles and paint finish. The
lifting point must be at the center of gravity to ensure that
the unit or unit section is level during hoisting and prior to
setting. When commencing to hoist, take up the slack in
the hoisting cables slowly and gradually increase the cable
tension until the full unit or unit section weight is suspended. Avoid sudden, jerking movements. Do not permit
the unit or unit section to be suspended by the lifting lugs
for an extended period of time. Once the unit or unit section leaves the trailer ensure it is level at all times.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
12”
12”
Pulleys
Adjustable
spreader bars
12” min.
Figure 2: Use adjustable spreader bars, pulleys and cables
attached to all lifting lugs to apply an even lifting force.
1. Set the unit, unit end or a bottom half of a horizontal
split unit end section with bottom duct connection of
a multi-section (modular) unit in place first.
IMPORTANT
The unit or a unit end section with bottom duct connection of a multi-section (modular) unit must be set
onto the curb first such that a gap of ½” [13 mm] is left
between the curb and the unit base frame on all outer
sides, as shown in Figure 3. Use ½” [13 mm] wood shims
to set the gap as shown in Figure 4. This is important, as
it will later on prevent the first section from sliding on the
curb towards the next sections, when pulling the multisection (modular) unit together and align the duct connection of the unit with the curb. Figure 4 shows a curb
mounted unit installation where the curb sits inside the
unit perimeter base and the unit base overhangs the curb
to prevent water entry.
For structural steel or pad mounting, if the dimensions of
the support is larger than the curb, then the end section
base must be positioned so the duct connection lines up
properly and then fastened to the structural steel or pad
to prevent the end section from moving when pulling
sections together. Fastening method must be determined
by the Installing Contractor. The lifting lugs on the outside perimeter may be removed with bolts and internal
nuts used to fasten unit to structural steel or pad. All
bolts should be returned and sealed to prevent leakage.
12
b. Set the upper or top section over the lower section lining up the bolt holes in the perimeter
flanges for a horizontally split indoor unit or section (see Figure 5b).
A
Figure 3: Set unit or an end section with bottom duct connection of a multi-section (modular) unit first using ½” [13
mm] wood shims on outer sides to properly position and
to prevent movement when pulling sections together.
Figure 5b: Set the upper or top section over the lower section lining up all the bolt holes in the perimeter flanges.
c. Use the 3/8” x 4” bolts, nuts and washers to secure
the upper or top section to the lower or bottom
section as shown in Figure 5c. Gradually tighten
all bolts to apply an even load along the external
joints (not at any point).
Temporary ½”
wood shim
(supplied by contractor)
Figure 4: Use ½” [13 mm] wood shims on outer sides to
properly position and/or to prevent movement when pulling multi-section (modular) units together.
Assembling a Multi-section (Modular) Unit
Special attention must be taken to ensure that a multisection (modular) unit has an air and water-tight seal at
every section split. Follow the next set of instructions for
assembling a multi-section (modular) unit.
2. For a horizontally split indoor unit or section:
a. Apply a continuous ½” [13 mm] bead of ADBOND
1465 acoustical butyl sealant on the top perimeter
of the lower or bottom section 1½” [38.1 mm]
from the outer edge as shown in Figure 5a.
½” [13 mm] bead of
ADBOND 1465
acoustical butyl sealant
Figure 5c: Use the 3/8” x 4” bolts ,nuts and washers and
gradually tighten to apply even load to secure sections.
CAUTION
Do not over tighten joint bolts as this may cause the bottom section frame to warp and break the air-tight seal.
3. Remove the yellow lifting lugs located on the section joint
(if any) once the first section is set in place.
IMPORTANT
1½”
Yellow lifting lugs located on the section joint (if any)
must be removed once the first section is set in place to
allow the next section to be pulled to the first.
1½”
Detail at A
Figure 5a: Apply a continuous ½” bead of butyl sealer on
the top perimeter of the lower or bottom section.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
4. Set the second section approximately 6” [152 mm] from
the first section (see Figure 6). If second section has
a horizontal split, the top section must be installed as
13
per procedure #2 above before proceeding. Use ½”
[13 mm] wood shims on outer sides to properly position and to prevent movement when pulling multisection (modular) unit together when mounted on a
roofcurb. Remove the yellow lifting lugs located on
the section joints (if any) from the second section to
allow sections to be pulled together.
7. Install the ½” x 1½” [13 x 38 mm] polyvinyl gasket
with adhesive strip directly on one side of the split
section perimeter frames and middle interior partitions as shown in Figure 8a through Figure 8e.
6” max.
8a, 8c
8d, 8e
8b
Figure 8: General gasket layout
IMPORTANT
Figure 6: Set the next section approximately 6” [152 mm]
from the first section.
5. Corner reinforcement brackets or angle bars may have
been used to support multi-section (modular) unit
walls during transportation, rigging and lifting at the
split. The brackets shown in Figure 7 are for larger
units. Simple angle bars are used for smaller units
(not shown). The corner reinforcement brackets or
angle bars are no longer required after rigging and
lifting and must be removed.
IMPORTANT
After the corner reinforcement brackets or angle bars
have been removed from the split section, set the screws
along with the rubber washers that were holding the
brackets or angle bars back in place for water-tightness.
Make sure to have full contact between strips wherever a
discontinuity is present, for air and water-tightness.
½” x 1½”
polyvinyl gasket
¼”
Figure 8a: Installapolyvinylgasketstriponeachverticaloutsidewall
¼” [6.4 mm] from the outside side edge from top to bottom of the side joint. When compressed, a small gap will
remain which will allow the Adseal 1800 series silicone
based sealant or equivalent to seal the vertical side edges
(explained in Figure 11).
Top of
frame
Bottom
of frame
Figure 7: Corner reinforcement brackets or angle bars to
be removed from the split section. Reset the screws with
rubber washer in place for water-tightness.
6. Verify that these two sections are aligned square at the
joint in all three directions.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Figure 8b: Install two horizontal polyvinyl gasket strips
along the base frame, one at the top and one at the bottom of the base frame, between the two vertical side gasket strips so there is full contact between gasket strips for
air and water-tightness.
14
Figure 8c: Install one horizontal polyvinyl gasket strip
along the top frame between the two vertical side gasket
strips so there is full contact between gasket strips for air
and water-tightness.
8. Use tools (chains, chain blocks, chain type come along,
etc.) connected to the side lifting lugs (attached to
the base) on both sides of the unit to pull the second
or next section to the first end section evenly until
both sections are ¼” [6.4 mm] apart on the full joint
perimeter as in Figure 9. Remove any exterior lifting
lugs that interfere with the chains for pulling sections
together. When joining sections together, always
apply the pulling force to the lifting lugs attached
to the unit structural base, never to the corner posts
and pull uniformly from both sides of the unit section. The butyl sealer previously applied on the roofcurb top surface will allow the unit section to slide
into position.
IMPORTANT
Unit sections must be drawn together using the lifting
lugs attached to the unit structural base only.
CAUTION
Do not use the vertical side casing framing or bolt holes
to pull sections together as this may cause the corner
posts to warp and break their air and water-tight seal.
Middle
internal
partition(s)/divider(s)
Displacement
Figure 8d: Wheretwoormoreinternalairtunnels/corridorsarepresent, install the gasket strips on the middle internal horizontal and/or vertical partition(s)/divider(s), between the
perimeter gasket strips so there is full contact between
gasket strips for air and water-tightness.
Tools supplied
by others
Figure 9: Use tools (chains, chain blocks, chain type come
along, etc.) hooked to the unit lifting lugs attached to the
structural base on both sides of the unit to pull the second
or next section to the first section evenly.
9. With the sections pulled together, use the 3/8” x
4” bolts, nuts and washers to secure the sections
together along the sides as in Figure 10. Start at the
bottom and gradually tighten all bolts to apply an
even load along both sides and for indoor units along
the top (not at one place) until sections or gasket is
compressed within ¼” [6.4 mm].
CAUTION
Figure 8e: Where a multi-sectional indoor unit with vertical and additional horizontal splits join, the middle internal
horizontal partition will require three gaskets. One at the
top of the bottom section and two at the bottom frame of
the top section.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Do not over tighten the side bolts as this may cause the
corner posts to warp and break their air and water-tight
seal.
15
Note: Cap should be on same j oint.
Figure 10: Secure the sections pulled together with bolts,
nuts and washers. Do not over tighten.
10. After two sections are assembled, verify that the assembly is level and square. If an adjustment is required,
make certain to address it immediately, not at the
end of the final assembly.
11. If multi-section unit has more than two sections, follow
Steps 2 through 9 for each additional section, always
pulling the next section from the first end section.
12. Apply a generous bead of Adseal 1800 series clear
silicone based sealant or equivalent to the exterior
side frame joint seams sufficiently to completely
cover the section split gasket and in such a way that
the silicone bead meets with both frames as in Figure
11. The bead of clear silicone based sealant should
fill the ¼” gap, as shown in Figure 11.
Figure 12a: Install the metal roof seam end with applied gasket by applying a 45° force to it until the neoprene is fully
compressed. Lock into position with two self-drilling 5/16”
hex head #12-14 x 1” screws with rubber washer until the
rubber washer is compressed. Repeat for other end.
Figure 12b: Always install the roof joint cap(s) end with two sideby-side pre-punched holes on the lower side of the roof
slope. Center and install the roof joint cap(s) with self-drilling 5/16” hex head #12-14 x 1” screws with integrated
gasket until the gasket is compressed in all pre-punched
holes.
If unit is wider than 138” [3,505 mm], roof slope is
double pitched from center and two or more roof
joint caps will be supplied (see Figure 12c).
¼” bead Adseal
1800 clear silicone
based sealant
Figure 11: Apply a continuous bead of Adseal 1800 clear
silicone based sealant or equivalent to the exterior side
frame joints and for indoor units along the top frame joints.
13. Install the roof joint caps with self-drilling screws in all
pre-punched holes for an air and water-tight seal
as shown in Figure 12a and Figure 12b (for outdoor
units only).
Figure 12c: Install middle joint cap at each roof joint cap
junction(s).
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
16
14. All lifting lugs removed on the exterior of the base
for pulling sections together must be returned or if
not desired the bolts must be set back in place. Once
removed, the bolts must be returned and sealed with
clear silicone based sealant for water-tightness. All
other lifting lugs from the unit base may be removed,
if desired, or left in place. When removing lifting
lugs on the exterior of the base, set the bolts back
in place and seal with clear silicone based sealant for
water-tightness.
15. Touch-up paint for scratches or marks to the external
finish incurred during shipment or installation can
be obtained in the fastest amount of time in bulk or
spray cans from a local paint supplier by providing
the universally recognized RAL code. To match the
Venmar CES standard grey specify color RAL K7 Classic #RAL7001, two-component polyurethane paint
with a gloss of 30+/−4.
Paint cans (11 ounces) matching the Venmar CES
grey can also be obtained in a slower amount of time
by contacting the following paint suppliers listed
below and providing the item number, item name
and Vendor number below or through Venmar CES
after sales service by: email to Tech Support at venmarservice@venmarces.com, fax 899-319-2612 or
phone 1-866-4-VENMAR.
In Canada
Sunamco
360 Gleme Rue C.P 280
Daveluyville, Quebec G0Z 1C0
Phone: 1-866-815-4080
Contact: Audrey Mallhot
Item number: 500049624
Item name: Canette peinture grise RAL7001
Vendor number: VEN00002429
In USA
Using the universally recognized RAL code
(RAL7001), Venmar CES Grey paint can be obtained
from your local supplier.
Hood Installation
If the intake or exhaust air hoods for the unit have been
shipped separately, they are assembled and fitted with
lifting plates for hoisting into position and holes are prepunched into the hood flanges for mounting. Apply a continuous length of 1/8” x 1” [3.2 x 25.4 mm] neoprene Soft
Seal gasket with adhesive strips to the hood flange perimeter and install with the 3/8” hex head #12–14 x 1” self-
drilling zinc plated screws supplied. Then apply a bead of
Adseal 1800 clear silicone based sealant or equivalent to
the outside perimeter of the hood flange for a water-tight
seal to the unit casing. If the hood lifting plate extension
is not desired, remove hood lifting plates, turn 180° and
screw back in place to fill holes to maintain paint finish.
Indoor Suspended Installation
To install indoor units that will be permanently suspended,
the units must be set on structural steel beams that are
supported by vertical rods. Venmar CES recommends
beams under the full perimeter and all cross members requiring support. In addition to these recommendations, a
Structural Engineer must be involved to properly size the
supporting structural elements. Note that the locations of
the beams shall be coordinated with the location of access
doors to prevent any interference (see Figure 13). Single
section unit shown; for multi-sectional unit suspension,
consult factory.
Anchor
40”
min.
40”
min.
Figure 13: Indoor suspended installation
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
17
Field Fabricated Ductwork
On outdoor bottom vertical duct connections, support all
ducts to the roofcurb and building structure. Do not support ductwork from the unit.
all duct connections to prevent air leakage and system
performance problems. Ductwork must be supported by
the building structure.
See Figure 14a for a curb mounted outdoor unit. Suggested methods of attaching ductwork to bottom of outdoor unit are as follows.
For bottom ductwork connections on pad or support steel
mounted indoor units, if the pad is larger than the inside
base frame of the unit, the bottom duct opening frame
is 1” above the bottom base of the unit (see Figure 14b).
If there is no access available to fasten ductwork flanges
with self-drilling sheet metal screws to the bottom frame
of unit duct opening, the pad opening must match the
ductwork opening and be raised by 1” to allow flanges on
ductwork plenums to seal to the bottom opening frame as
described for outdoor units.
•
•
•
Attach ½” x 1½” polyvinyl gasket with adhesive back
to ductwork flanges and fasten ductwork flanges
with self-drilling sheet metal screws to bottom frame
of unit duct opening where access to bottom of unit
is available once unit is installed. Ductwork must be
supported by building structure.
Field provide and install ductwork supports across perimeter curb frame and/or cross members level with
top of perimeter curb, install ductwork plenums with
top perimeter flanges in supports and fasten with
self-drilling sheet metal screws. Attach ½” x 1½”
polyvinyl gasket to ductwork flanges prior to setting
unit on roofcurb.
Field provide and install ductwork curb level with
top of perimeter curb, install ductwork plenums in
ductwork curb with top perimeter flanges and fasten with self-drilling sheet metal screws. Attach ½”
x 1½” polyvinyl gasket to ductwork flanges prior to
setting unit on roofcurb.
½” x 1½” polyvinyl gasket
1”
Figure 14b: Bottom field fabricated ductwork connection
for indoor pad mounted units
½” x 1½” polyvinyl gasket
Figure 14a: Bottom field fabricated ductwork connection
for outdoor curb mounted units
On horizontal or indoor vertical duct connections, make
connections to the casing by applying Adseal 1800 silicone
based sealant or equivalent around the connection and
screwing flanged ducts directly to the casing and/or flange
with self-drilling sheet metal screws. It is important to seal
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
For duct connection sizes, see the mechanical drawings.
Insulate and weatherproof all external ductwork, joints
and roof openings with counter-flashing and mastic in
accordance with applicable codes. Ductwork running
through roof decks must comply with local fire codes.
Ducts passing through unconditioned spaces must be insulated and covered with a vapor barrier. Flexible connectors
should be installed close to the unit in the duct leading to
occupied spaces to minimize noise transmission.
The design of the ductwork immediately downstream of
the gas-fired furnace is critical for successful applications.
Poorly designed ductwork can contribute to excessive
temperature fluctuations. Avoid splitting or branching of
the ductwork immediately downstream or within five duct
diameters from the discharge where temperature stratifications may exist.
The design of the ductwork immediately downstream of
a double width forward curved or backward inclined fan
is critical to the performance of the fan. The velocity profile at the outlet of the fan is not uniform and an elbow
located at or near the fan outlet will, therefore, develop
18
a pressure loss greater than its ”handbook” value and
must be included in the external static pressure calculations. Consult the AMCA Fan Application Manual publication 201 for recommendations and system static pressure
losses.
The ventilation system should be designed according to
maximum airflow needs. To minimize noise level and loss
of pressure, ducts should be designed for a maximum air
velocity of 1,200 feet per minute, keeping the direction
and transition changes to a minimum. To further reduce
noise transmission, line the first 15 feet [4,572 mm] of
duct with acoustic insulation. Elbows with a turning radius
equal to or greater than one, or 90° elbows with turning
vanes, should also be used.
When an Energy Recovery Ventilator (ERV) is installed in
conjunction with a forced air system Air Handling Unit
(AHU), the AHU and network of ducts are used to supply fresh air inside the building. In this type of system, the
main fan of the AHU must be in continuous operation
when the ERV is on. Supply air from the ERV should be
introduced into the return duct of the AHU no less than 6
feet [1,829 mm] upstream from the AHU. The ERV return
duct connection should be at least 2 feet [610 mm] upstream of the ERV supply air duct connection in the AHU
return duct.
Electrical Connections
!
WARNING
When installed, the unit must be electrically grounded in
accordance with local codes or, in the absence of local
codes, with the National Electrical Code, ANSI/NFPA70,
and/or the Canadian Electrical Code CSA C22.1. Unit
cabinet must have an uninterrupted, unbroken electrical
ground to minimize the possibility of personal injury if an
electrical fault should occur. Failure to follow this warning could result in the Installer being liable for personal
injury of others.
The unit is factory wired (unless otherwise specified)
except for power connections, shipping split locations,
shipped loose sensors/items or remote control options
as indicated in the electrical schematics and sequence of
control. The unit may or may not have an optional factory
installed door interlocking disconnect in the control panel.
If the unit control panel disconnect is not supplied, the
Electrical Contractor must provide and install disconnect
outside of the unit as per local electrical codes and run the
power supply wiring to the control panel.
•
For multi-section (modular) units, the Electrical Contractor must join the low and high voltage wiring between sections at the junction boxes or extend coiled
wiring.
IMPORTANT
Wire nuts and electrical butt connectors (if required) must
be supplied by the Electrical Contractor.
•
•
Check nameplate for correct power supply requirements.
See electrical schematics and sequence of control
located in the control panel pocket for field wiring of
power connections, shipped loose sensors, items or
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
•
•
•
•
•
•
remote control interlocks. The Electrical Contractor
must locate, install and wire sensors, items or remote
control interlocks as per electrical schematics and sequence of control.
Numbered terminals strips are included in the control
panel for ease of connection and service.
All field wiring and components must comply with
NEC and local requirements. In Canada, electrical
connections must be in accordance with CSA C22.1
Canadian Electrical Code Part One.
Install copper wiring of proper size to handle current
load.
The base unit control includes an external contact
and is not equipped with a remote control panel.
This contact is located in the unit control panel. The
Installer must connect the external contact to a controller normally located in the building. This controller
can be a humidistat, switch or timer, etc. Optional
controls are 24 VAC.
The remote control panel is optional and when included has numbered terminals matching the unit
control panel terminals. Use wiring equal to AWG18
to connect like-numbered terminals.
Mounting of field provided components in the control panel is allowed as long as their space was considered during the submittal process. Non-considered
electrical components are not allowed in the control
panel. It is the responsibility of the Control Contractor to provide his own power source(s) for any field
added electrical components. The control panel
mounted transformers are not rated for external
components power supply unless otherwise listed on
the electrical schematics.
19
Electrical Field Connections
CAUTION
Electrical components and contacts must be protected
from damaging metal shavings before drilling holes into
the control panel. Use liquid-tight connections through
the control panel and unit casing eliminating any water
and air penetration.
Shipped loose sensors, items or remote control wiring
can be located next to the power feed cable provided it
is inserted in shielded cable that will protect it from electromechanical interference. Ensure the power feed cable
ground is securely connected to the terminals located in
the control panel.
Electrical Contractor must provide wiring for controls that
are supplied optionally and shipped loose or field supplied.
Mark the electrical schematic with the connections completed and leave them with the unit for start-up and service.
CAUTION
High voltage power lines, shipped loose sensors, items
or remote control option field wiring entry points may
only be field extended through the cabinet within designated areas. The unit cabinet and/or floor must be
wisely penetrated in order to keep their integrity. Access
openings in the floor can only be cut or drilled for piping
and wiring (high and low voltage) in the designated rectangular areas within an upturned 1” [25.4 mm] flange
as provided during the submittal process and located on
the mechanical drawings. Access openings must be sized,
field cut or drilled by the Installing Contractor within the
rectangular flanged area then sealed air and water-tight.
If insulation was removed to create floor access openings,
insulation must be put back in place to avoid condensation. Do not cut or drill holes through floor of unit in
non-designated areas without consulting the factory first.
The structural integrity of the floor may be compromised
and possible leaks develop.
Coil, WSHP or Humidifier Piping Connections
CAUTION
Internal coil (water, steam or non-integrated direct
expansion), WSHP or humidifier piping connections
within the unit may only be field extended through the
cabinet within designated areas. The unit cabinet and/
or floor must be wisely penetrated in order to keep their
integrity. Access openings in the floor can only be cut
or drilled for piping and wiring (high and low voltage)
in the designated rectangular areas within an upturned
1” [25.4 mm] flange as provided during the submittal
process and located on the mechanical drawings. Access
openings must be sized, field cut or drilled by the Installing Contractor within the rectangular flanged area then
sealed air and water-tight. If insulation was removed to
create floor access openings, insulation must be put back
in place to avoid condensation. Do not cut or drill holes
through floor of unit in non-designated areas without
consulting the factory first. The structural integrity of the
floor may be compromised and possible leaks develop.
Connections to the unit coil (water, steam or non-integrated direct expansion, WSHP or humidifier) are by others. Refer to the mechanical drawings and the instructions
on the casing for correct orientation of external piping.
External supply and return piping connection, provision,
design and all other safety, freeze protection or electrical
control requirements for system operation are the sole
responsibility of the Installing Contractor and/or Design
Engineer. Refer to ASHRAE handbooks and local building
codes for correct piping and electrical control for proper
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
installations. Refer to the mechanical drawings for coil performance design information.
For WSHP units see Appendix B for recommended piping
and electrical control components. See the piping schematics for optional piping components and sequence of
operation for electrical control options or interlocks supplied with the unit.
CAUTION
A water and glycol mixture is used for factory tests and
to prevent any possibility of freezing during transit and/
or storage. In units that include factory installed water
piping, some glycol may remain in the system. Flush the
system in the field, prior to installation, if no glycol traces
are desired. In low temperature applications, the water
supply line and return line should be insulated to prevent
condensate and an antifreeze solution should be used to
protect water-to-refrigerant heat exchanger from freezing damage.
IMPORTANT
A hydrostatic test must be performed in the field by the
Installing Contractor at 1.2 times the operating pressure
on all equipment involving piping connections to verify
that the installed unit and its connections to the network
are free of leaks prior to the unit being set in operation.
This test shall be performed after the unit is completely
piped to the network and shall cover the connections
between the unit and the network, as well as all internal
components of the unit.
20
Condensate Drain Trap and Lines
Cooling coils, humidifiers, sensible heat exchangers or
other options that can produce condensation are provided
with a drain pan with a 1¼” [32 mm] MPT (Male Pipe
Thread) drain connection. A drain trap and condensate
line of equal size must be field provided by the Installing
Contractor on the drain connections and coupled to the
building drainage system to prevent air or sewer gases
from being pulled into the unit caused by the negative
(suction) pressure and forcing water out of the pan into
the unit or from air escaping into the drain caused by
positive pressure. Condensate piping can be steel, copper
or PVC. See Appendix C for illustrations and dimensional
information on positive and negative pressure trapping
height. Slope the drain lines downward in direction of
flow not less than 1/8” per foot toward the building drainage system; otherwise use a condensate pump. Refer to
local codes for proper drainage requirements. Installing
a plug for cleaning of the trap is recommended. Fill the
P-traps with water before starting the unit. Winterize the
drain line before freezing on outdoor units. Under some
conditions, heat tracing may be required on the drain
pipe.
Check and clear drains annually at start of cooling season.
Drainage problems can occur should drains be inactive
and dry out, or due to reduced water flow caused by
buildup of algae. Regular maintenance will prevent these
from occurring.
Gas Connections
Refer to Appendix D for gas-fired furnace installation and
maintenance information.
Refrigerant Systems
On assembled units which are split for shipment or by
customer request, where the refrigeration system is split,
the refrigerant lines are capped at the splits, factory leak
tested and charged with nitrogen. The type of refrigerant
and charge is based on calculated volumetric capacity and
stamped on the nameplate. The Installing Contractor is responsible for connecting the refrigerant lines, leak testing,
evacuation, charging the refrigerant system and adjusting
the charge.
On assembled units with split refrigerant systems where
the condenser or condenser/compressor sections are remotely installed, the Installing Contractor is responsible
for designing and completing the refrigerant system, calculating the charge, leak testing, evacuation, charging the
refrigeration and adjusting the charge.
Refer to Appendix P for information on adjusting the refrigerant charge.
Start-up
Pre Start-up Check
Before requesting start-up, check that the installation is
complete and unit is ready. Complete the pre start-up
below (if items are applicable) and the checklist in Appendix E for each unit. For torque values on set screws, belt
tension, energy wheel seal clearance, etc. check under the
appropriate Maintenance and/or Appendix sections.
1. Check the electrical disconnect is in the ‘Off’ position.
2. Check the split section joints are properly installed on
multi-section units.
3. Check that all holes that have been made by the
Installing Contractor after receiving the unit in the
casing, partitions or floor have been well sealed to
prevent air and/or water infiltration.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
4. Check the unit for obstructive packaging, objects
near or in fans, dampers, energy recovery wheel, etc.
a. Check that the inside of the unit has been
cleaned of all debris.
5. Remove all retaining bolts on fan isolation bases.
a. Check that the fan impellers are rotating freely.
b. Check fan impeller and drive set screws. Tighten
if required.
c. Check the fan bearing set screws or locking collars. Tighten if required.
d. Check fan belt alignment and tension.
e. Check the fan flexible joint connections are well
attached.
21
6. Check that the air filters are installed and clean.
Replace if necessary. See Appendix F for optional
downstream high efficiency HEPA filter installation (if
supplied).
a. Check all face mounted filters are attached with
four clips each.
b. Check each sliding filter has a retainer at the end
track and well attached blank-offs.
c. Check the filter pressure differential gauges,
switches or sensors are free of dirt and set at a
value satisfactory to the end user to trigger a filter change.
7. Check coils if fins have been damaged in shipping,
installation or building construction and are clean.
Straighten fins with fin comb and clean coil if required
(not applicable to brazed aluminum heat exchangers).
a. Check all pipe connections are tight and that
no damage has occurred during shipping or
installation.
b. Check that the piping to the coils and WSHP
have been completed, piping lines have been
flushed, filled, vented and tested at 1.2 times the
operating pressure. Refer to Appendix B.
8. Scroll compressor RIS vibration isolator bolts are factory tightened to the correct torque setting for operation and do not require field adjustment.
a. Check the refrigerant components and piping are
in good condition and have no damage or leaks
from shipping or installation.
b. Check that the refrigerant lines are spaced at least
1” apart and from the compressor after shipping
and installation.
c. Check that the refrigerant line clamps are still secure
and have their rubber lining.
d. Check that the clearance around the air cooled
condenser is within minimum clearance and the
discharge is not blocked.
9. Check motorized damper control arms, control rods
and shafts for tightness.
a. Check that non-motorized dampers rotate freely.
10. Check the energy recovery wheel media for any defects from shipping or installation. See Maintenance
section for details.
a. Grease both pillow block bearings on the
wheel(s) when grease nipples provided.
b. Check that the wheel(s) are turning freely by
hand and do not bind.
c. Visually inspect the wheel(s) to ensure it is centered and does not tilt. If there is any indication
of a problem call Venmar CES Tech Support at
1-866-4-VENMAR.
d. Check that the wheel seals are properly positioned from the face of the wheel.
e. Check that the wheel purge (if present) is set to
the default angle as specified in the submittal.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
f. Check the mounting fasteners on the wheel(s)
motor and gear reducer are tight.
g. Check the belt and pulley on the wheel drive for
correct alignment, tension and set screw tightness.
11. Check the plate media for any defects from shipping
or installation.
12. Check the heat pipe fins for any defects from shipping or installation.
a. Remove retaining bolts on heat pipe tilt mechanism.
b. Check the heat pipe flexible connection is properly attached and sealed on tilt mechanisms.
c. Check that actuator, control arm and linkages
are tight on tilt mechanism.
13. Check that ductwork is connected, complete and
free of obstructions.
14. Check that condensate drain connections have been
trapped, installed correctly and filled.
15. Check at all unit split sections that all factory internal
high and low voltage wiring connections have been
properly re-connected.
16. Check that all shipped loose or field supplied components have been correctly installed and wired.
17. Check that the wiring diagram has been marked up
accordingly and left with the unit.
18. Check that all power supplies and control wiring
have been inspected and approved by the Local Authorities having jurisdiction.
19. Check all factory and field wiring connections for
tightness. Tighten if necessary.
20. Check that all fuses are properly installed in holders.
21. Check the voltage at the disconnect switch against the
nameplate and against phase-to-phase readings on
three-phase. If the voltage is not within 10% of rated
or 2% of phase-to-phase, have the condition corrected before continuing start-up.
22. Check that all field piping and venting installation
and connections for the heating and cooling options
have been completed and tested.
23. Set the heating and cooling enable switches to the
‘Off’ position.
24. Refer to Appendix D for gas-fired furnace module
and Appendix G for electric coil installation and
maintenance and check that the installation is complete. Perform all gas-fired furnace and electric coil
pre start-up checks.
25. Check that all safety switches, overloads or other
manual reset devices are reset.
26. If the unit is equipped with compressors, power must be
turned on with the unit in ‘Off’ mode for 24 hours
before start-up. This will energize crankcase heaters and assure no liquid refrigerant is present which
could cause compressor damage or failure. Check
that this has been completed.
22
Start-up Procedure
To ensure proper operation of each unit, qualified personnel should perform the start-up as outlined below (based
on options included with unit) and complete the Start-up
Report and Checklist in Appendix E for permanent record.
A completed report and checklist will provide valuable information for personnel performing future maintenance.
•
•
•
•
IMPORTANT
A completed copy of the Start-up Report and
Checklist must be sent back to the factory for warranty validation and for factory assistance.
General information on the factory installed and
programmed DDC control system regarding the
navigation and monitoring of the unit with the
standard keypad are provided in separate documents. For more specific information regarding the
sequence of control, the different options of control
or network communications, see these documents
included with the unit in the control panel pocket.
If units are equipped with compressors power must
be turned on for 24 hours prior to a call for cooling,
for the compressor crank case heaters to be energizing to prevent possible damage.
Assembled units with integrated refrigerant systems (AC, WSHP or ASHP) are factory leak tested,
charged with refrigerant based on volumetric capacity and run tested prior to shipment with the type of
refrigerant and charge stamped on the nameplate.
As part of the start-up procedure, operate the refrigerant system near full load conditions in both
heating and cooling modes and check sub-cooling
and superheat against values in Appendix P, Table
P1. If readings do not match, adjust the refrigeration charge. Refer to Appendix P for information on
adjusting the refrigerant charge.
!
•
•
•
•
WARNING
Electric shock can cause personal injury or death.
Only qualified service personnel should install and
service this equipment.
The keypad must be used to check operation according to sequence and to adjust setpoints while power
is on for start-up and while performing service.
All units are factory run tested. Fans, energy recovery wheel, compressors and condenser fans
(if equipped and refrigerant piping is not split for
shipment) are set up to run correct when power
is connected. If any one fan is running backwards
or compressor is making loud noises, disconnect
power and switch two leads (on three-phase power)
to ensure proper rotation and avoid damage. With
multi-section units with split wiring connections
check rotation of fans, energy recovery wheel, compressors and condenser fans for correct rotation to
ensure wiring connections are correct.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
1. Before proceeding, complete the pre start-up checklist.
2. Check that all access panels or doors are closed.
3. If units are equipped with compressors, feel the
compressor crank cases. They should be warm if the
disconnect has been on for at least 24 hours. This
will assure that no refrigerant liquid is present in the
crank case which could cause compressor damage or
failure to occur on start-up. Otherwise turn the main
disconnect to the ‘On’ position.
4. The unit can be started by using the keypad and
selecting the mode of operation from the Keypad
Operation Guide and the Sequence of Operation.
Disable the heating and cooling functions and set
the unit to the occupied mode to bump start the fan
wheel(s) and energy recovery wheel(s) to check their
operation.
5. Check that dampers are operating properly.
6. Check that the fan wheel(s) and energy recovery
wheel(s) are rotating in the correct direction.
7. Adjust the fan motor VFD(s) to the correct air volume/Hertz/
8. For occupied recirculation mode adjust outside, exhaust and mixed or recirculation air damper positioners to achieve the required air volumes.
9. Check amperage draw to each motor on each phase
against motor nameplate FLA. If significantly different,
check ductwork static and/or take corrective action.
10. Re-check the voltage at the disconnect switch against
the nameplate and against phase-to-phase readings
on three-phase with all blowers operating. If the
voltage is not within 10% of rated or 2% of phaseto-phase, have the condition corrected before continuing start-up.
11. Before activating the compressor on WSHP units,
check that the water shut-off valves are open and
water is circulating through the water-to-refrigerant
heat exchanger. Check the incoming line water pressure to ensure it is within design and acceptable
limits.
12. Enable the cooling mode of operation. Check if the
sound of the compressor is normal or if there is excessive vibration.
13. On units with integrated air cooled condensers check
condenser fans are rotating in the correct direction.
14. Check all field and factory refrigerant and water piping connections for leaks and correct.
15. Operate the refrigerant system near full load conditions in both heating and cooling modes and check
sub-cooling and superheat against values in Appendix P, Table P1. If readings do not match, adjust the
refrigerant charge. Refer to Appendix P for information on adjusting the refrigeration charge.
16. On units with WSHP, after a few minutes of operation:
a. Check the supply discharge temperature status
on the keypad for cooling air delivery. Measure
23
the temperature difference between entering
and leaving water. In cooling mode, the temperature difference should be approximately 1.5
times greater than the heating mode temperature difference. For example, if the cooling temperature difference is 15°F [8.3°C], the heating
temperature difference should be approximately
7°F to 10°F [3.9°C to 5.6°C]. Alternatively, if a
flow measuring valve or pressure gauge connections are included, take the flow reading or
pressure drop compared to the submittal information and adjust the shut-off/balancing valve in
the return line to the correct flow/pressure drop
reading.
b. Measure the temperature difference between
entering and leaving air and entering and leaving water. With entering water of 60°F to 80°F
[15.6°C to 26.7°C], leaving temperature should
rise through the unit. Should not exceed 35°F
[19.4°C]. If the air temperature exceeds 35°F
[19.4°C], then the water flow rate is inadequate
or the airflow rate may be low and a second
check may be required after airflow balancing.
17. On units with gas-fired furnace module or electric
heating coils, check supply air proving interlock
switch setting to ensure minimum supply airflow
prior to burner operation. Set the switch to open
below the minimum supply airflow on the furnace
rating plate.
18. Enable heating options, see start-up and check-out
instructions in Appendix D for gas-fired furnace module and Appendix G for electric coil and complete.
19. For electric heating coil option, check the amp draw
on each stage, the operation of the sequence or SCR
controller and the coil for any hot spots.
20. Check the operation of the control options provided
on the unit.
21. Check the setpoints on the DDC Points Reference,
adjust and record changes as required.
22. Has air balancing been completed for both occupied
and unoccupied operation?
23. When unit has achieved steady state, take measurements and complete Start-up Readings portion of the
Start-up Report and Checklist in Appendix E. Send a
copy of the completed Start-up Report and Checklist
to Venmar CES to validate warranty. Maintain a copy
of the report at the unit for future reference.
24. Once completed, return setpoints to original or required values, return the unit to the correct mode of
operation and adjust the time clock if required.
Airflow Balancing
IMPORTANT
Before measuring supply and exhaust flows, the building
must be in its normal state:
•
•
•
Hermetically close doors and windows.
Shut down hot air generators and combustion
water heaters.
Install all ventilation system components (filters,
grilles, diffusers, etc.).
For proper performance the unit must operate at the specified supply and exhaust flow rates as shown in the mechanical drawings. Unit fan speed(s) and damper positions
are theoretically set at the factory based on the ductwork
static pressures and flow rates specified in the mechanical
drawings. If conditions change or verification is required,
airflow measurements should be taken using AMCA suggested methods. This would normally be a velocity traverse
measurement or flow measuring station (FMS) installed in
the ducts. Where space is limited in the outdoor air and
exhaust air, pressure drop readings can be taken across
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
the energy recovery heat exchanger (with economizer heat
recovery bypass dampers closed, if equipped) and compared to the submittal documents. Heat recovery performance is tested in accordance to AHRI Standard 1060 and
is accurate to within +/− 5% if there is no dirt buildup in
the heat recovery heat exchanger. Should flow rates need
to be reset, adjust the outside air, exhaust air or mixed air
dampers, variable speed sheaves, VFD fan speed setpoint
positions or change the sheaves.
Flow measuring stations and magnehelic gauges can also
be used to measure supply and exhaust flow. It is important to locate the FMS in the “warm side” ductwork to
minimize the effect of differences in air density, especially
when balancing during extremely cold outside conditions
or to take temperature readings and make the necessary
corrections if installed in the “cold side” ductwork. Air
density variations can affect the FMS by more than 15%.
The FMS should be located downstream in straight sections of duct and not immediately after fans or obstructions that will cause turbulent flow.
24
If the unit has been in operation before the air balancing,
ensure the unit filters are clean or include pressure drop
readings across the filter banks with the report.
Refer to Appendix D for gas-fired furnace module air balancing information. The installation is to be adjusted to
achieve the air throughput within the range specified on
the gas-fired furnace module rating plate.
CAUTION
Imbalanced airflows may cause supply air temperatures
to be below freezing. Adequate freeze protection, glycol,
low limit temperature protection for downstream coils or
reheat to protect building systems must be field provided.
Maintenance
Long-term Storage Maintenance Procedures
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
Please refer to Appendix H for maintenance instructions
to follow if the unit is to be stored for a period of time exceeding one month. Following the instructions in this appendix will assist in preventing potential unit damage that
may result from an extended storage period.
Maintenance Summary Chart
Please refer to Appendix I, for a recommended list of
routine maintenance items and time intervals. A more detailed description of maintenance items follows.
Energy Recovery Wheel
The energy recovery wheel will provide years of effective
and efficient service with minimal maintenance. Basic
maintenance consists of checking parts to ensure they are
tight and working correctly. Venmar CES recommends
that the wheel be checked on a weekly basis that it is
turning under power if not equipped with a rotation detector alarm. Completing the items described further in
the Maintenance Summary Chart in Appendix I will ensure
the wheel is running at its maximum efficiency and assist
with the early detection of anything that may cause problems in the future. If removal or replacement does become
necessary contact the factory for instructions.
E/A
Outside side
O/A
Outside/supply
air side
Spoke
Seal
Casing
Media
segment
Purge
Return/exhaust
air side
Driving
belt
Motor
base
Enthalpy
wheel
Figure 16: Labeled diagram of wheel
R/A
Purge side
Purge
Rotation
S/A
Figure 15: Direction of airflow through the wheel
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Wheel Bearing Lubrication
Recommended lubrication of bearings (when grease
nipples provided) varies depending on the temperature
range the wheel will be used in. For a typical temperature
range of −40°F to 130°F [−40°C to 54°C], lubrication is
recommended every six months. For temperatures out of
25
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
this range, please consult Venmar CES for recommended
lubrication schedules. Use a premium quality lithium based
grease conforming to NLGI Grade 2 or 3 (examples are:
Mobil – Mobilith AW2, Chevron – Amolith #2, Texaco Premium RB, Shell Alvania #2).
Wheel Bearing Set Screws
Bearing set screws and mounting bolts (two on each side
of the wheel) should be checked for tightness at start-up
and every six months thereafter. On wheels 10” deep a
special seal lacquer is applied to the bearing set screws and
mounting bolts. See Figure 17. This is a visual aid that will
warn you if bearing set screws or mounting bolts have become loose during transport or over time should cracks appear. Set screws should be torqued to 13 ft-lb for wheels
up to 78” [1,981 mm] diameter and 24 ft-lb for wheels
from 88” to 120” [2,235 to 3,048 mm] in diameter.
Figure 17: Enthalpy wheel seal laquer
Gearbox
Belts
The energy recovery wheel drive belt is a strong and flexible multi-link which provides quick and easy servicing
or replacement without using special tools. The belt is
directional; it must be installed with the directional arrows
pointing in the direction of motor rotation. See Appendix
K for belt repair and replacement instructions. Checking
the belt every three months for wear is recommended.
Belt Installation
1. Consult Venmar CES for belt length (dependent
upon wheel diameter).
2. If required, remove links by twisting the link tabs
sideways and pulling the surplus out of the belt.
3. Tape one end of the new belt to the wheel and make
it turn (by hand) one complete revolution. Place tapes
on the belt to ensure its proper upright position
and hold it in place until it will be linked. The wheel
should turn freely if the belt is removed.
4. Pull the belt tightly around the wheel and reducer
sheave.
5. To connect the two free ends of the belt, hold the belt
with tabs pointing outward. Place the end tab
through two links at once. Flex the belt further and
insert the second tab through end link by twisting
the tab with your thumb. Ensure tab returns to position across belt. Reverse belt so tabs turn to the inside of belt.
6. Depending on type of wheel provided, install the extension spring or pass the belt over the tensioner idler
sheave. If there is no tension in the spring or tensioner, reduce the length of the belt. If the spring
tensioner looks permanently extended, contact the
factory for a replacement spring tensioner.
Belt Tensioner Replacement
1. Release the belt from the belt tensioner idler sheave,
Figure 18.
The gearbox (speed reducer) on the energy recovery wheel
has been lubricated for life at the factory and requires no
further lubrication. The gearbox requires no maintenance
under normal use.
Motor Bolts
Bolts securing the motor to the base plate should be
checked periodically for tightness at start-up, after one
month of operation and annually thereafter (see Table 1
for recommended torque).
Figure 18: Release belt from belt tensioner idler sheave
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
26
!
WARNING
Seals
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
Side seal
2. Remove the belt tensioner retaining screw and set
aside (see Figure 19).
Peripheral
seal
Airloop™
labyrinth seal
Airloop™
labyrinth seal
Figure 21: Energy recovery wheel seal locations
Figure 19: Remove belt tensioner retaining screw
3. Remove belt tensioner and discard. Install new belt
tensioner (contact Venmar CES Tech Support at
1-866-4-VENMAR for parts using description and
unit serial number).
4. Ensure that the new belt tensioner line is aligned
with one of the bottom corners (see Figure 20).
IMPORTANT
The idler sheave must be pointing upwards.
Depending on size and type of wheel, brush or labyrinth
seals are provided. Visually inspect the seals of the energy
recovery wheel(s) for proper operation. Brush seals for
the side and peripheral seals per Figure 21 are designed
to be durable and require no maintenance, but some seal
run-in is to be expected, so do not be alarmed by a small
amount of wear. Labyrinth seals must be adjusted properly
if the unit is to work effectively and efficiently; the correct
adjustment of the labyrinth seal is obtained by allowing
it to barely touch the media before tightening the screws
(see Figure 22). If an initial gap can be seen between the
seal and media, the seal is installed too far and should
be moved closer until it touches the media. On the other
hand, if any deformation to the lips can be seen, it means
the seal is installed too close and should be moved back
until the lips are straight again.
It should be noted that the labyrinth seal is made of a special material which was specifically chosen to make sure it
could never damage the media. While the best seal is obtained when the above steps are followed, if installed too
close, the media will simply use the seal a little more.
As the wheel turns, the seal will automatically adjust itself
to the wheel’s tolerance (approximately 1/32”) for the
smallest possible air leakage and become a non-contact
seal that will last throughout the wheel life.
To ensure optimal performance, seals should be checked
at time of start-up, after one month of operation and
every three months thereafter. Labyrinth seals, if found to
be out of tolerance, should be adjusted immediately.
Figure 20: Energy recovery wheel seal locations
5. Reinstall and tighten screw.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
27
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
d2
Wheel media
Correct
d2 = 0” (start-up)
d2’ = Wheel tolerance
Wrong
Too
far
The opposing airflow pattern through the wheel allows
for self-cleaning and if the air filters on both airstreams are
properly maintained there should be minimal dirt buildup.
If the wheel media has become restricted with dirt and
needs cleaning use low pressure (20 psi maximum) compressed air or vacuum. If this is insufficient, please contact
the factory for further instructions. When cleaning the
wheel, protect the motor and other components from
contamination. Solvents or detergents are not recommended for use as they may degrade the binding used for
the desiccant in the media.
CAUTION
Energy recovery wheel cleaning is an important part of
routine maintenance. The listed methods of cleaning have
been found effective, if done properly. However, any
method of cleaning has the potential to cause damage to
an enthalpy wheel media or desiccant if done improperly.
Venmar CES is not liable for any damage caused as
a result of energy recovery wheel cleaning.
Wrong
Too
close
Figure 22: Airloop™ labyrinth seal adjustment
Wheel Media
Periodic checking of the media, rim, spokes and shaft is
very important in maintaining optimal performance of the
wheel. To check the media, the wheel must be shut down.
The media should be checked for tightness at start-up,
after the first 30 days of operation, then by three month
intervals. The best method to test for tightness is to place
your hands against the media, near the hub, and try to
move it up and down on both sides. This procedure should
be used on all segments of the wheel. If any movement, in
any direction, is detected on any segment, contact Venmar
CES immediately.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
28
Flat Plate Heat/Enthalpy Exchangers
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
Venmar CES offers four types of plate heat/enthalpy exchangers. They are factory installed and ready to use upon
receipt. Based on long experience, dirt buildup inside the
plate heat exchangers installed in air handling equipment
is not expected, provided the air filters on both airstreams
are properly maintained. Plate heat exchangers should be
visually checked monthly for dirt buildup on the entering face for the initial three months after installation and
start-up, after which checks should be carried out every 12
months. During normal operation or when used for special applications (e.g. welding shops, paint shops, kitchen
extracts, etc.), should dirt enter the plate heat exchanger,
if pressure differential between exchanger inlet and outlet is higher than stated at the design airflow, clean the
exchanger using techniques mentioned below. If after
cleanup, the pressure differential is still higher than stated
at the design airflow, contact Venmar CES.
Extruded polypropylene and corrugated or embossed
aluminum plate heat exchangers should be cleaned by
removing dust and fibers with a soft brush, a vacuum
cleaner or with dry compressed air at 90–95 psi and
12”[305 mm] from the surface. Take care when cleaning
with compressed air that the exchanger is not damaged
and that oil contained in the compressed air is not pushed
inside. Oils, solvents, etc. can be removed with hot water,
harmless grease solvents or cleansing agents by washing.
If using a high pressure device use a flat 40° nozzle (type
WEG40/04) with a maximum water pressure of 1,450 psi
[100 bar] and 12” [305 mm] from the surface. Take care
when cleaning with water, solvents or cleaning agents
that the exchanger is not damaged, either mechanically or
chemically.
Enthalpy (sensible and latent) plate heat exchanger core
is constructed of alternate layers of corrugated aluminum
material and polymeric desiccant impregnated media and
should be cleaned by removing dust with a soft brush or
with a vacuum cleaner only.
CAUTION
Do not use compressed air or water to clean an enthalpy
plate heat exchanger as irreparable damage may occur.
Heat Pipe Heat Exchangers
Heat pipes are factory installed and ready to use upon
receipt. Based on long experience, dirt buildup inside
the heat pipe heat exchangers installed in air handling
equipment is not expected, provided the air filters on
both airstreams are properly maintained. Heat pipe heat
exchangers should be visually checked monthly for dirt
buildup on the entering face for the initial three months
after installation and start-up, after which checks should
be carried out every 12 months.
During normal operation or when used for special applications (e.g. welding shops, paint shops, kitchen extracts,
etc.), should dirt enter the heat pipe heat exchanger, if
pressure differential between exchanger inlet and outlet
is higher than stated at the design airflow, clean the exchanger by removing dust and fibers with a soft brush, or
with a vacuum cleaner. Oils, solvents, etc. can be removed
with hot water, grease solvents or cleansing agents by
washing. Choose harmless grease solvents or cleansing
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
agents in accordance with the heat exchanger material (raw aluminum or coated tubes) such that they will
not contaminate or release volatile organic compounds
(VOCs) into the treated air and area(s) the unit serves. If
using a high pressure device, use a flat 40° nozzle (type
WEG40/04) with a maximum water pressure of 1,450 psi
[100 bar] and 12” [305 mm] from the surface. Take care
when cleaning with water, solvents or cleaning agents
that the exchanger is not damaged, either mechanically or
chemically. If after cleanup, the pressure differential is still
higher than stated at design airflow, contact Venmar CES.
If the heat pipe heat exchanger is equipped with a tilting
mechanism, the linkage, actuator mounting attachments,
bearing attachments and flexible connection attachments
and condition should be checked for tightness before
start-up, after the first week of operation, then on three
month intervals.
29
Refrigerant Systems
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
Compressors
Scroll type compressors are the most common type of
compressor used by Venmar CES. Other types of compressors are available upon request, if required.
Maintenance and service on compressors must be completed by a licensed service mechanic. Provincial or state
regulations frequently require such qualifications for compressor maintenance.
If a compressor cycles, leaks or has any defects, contact
Venmar CES as soon as possible.
See Appendix B for compressor maintenance and troubleshooting refrigerant circuits and Appendix P for adjusting
refrigerant charge. Additional refrigerant troubleshooting
issues can be found in Appendix O.
Condenser
Condenser Fans and Motors, Air Cooled
The units contain direct drive condenser fan and motor
assemblies. The condenser fans are multi-blade propeller
type with die cast silumin alloy hub and glass reinforced
polypropylene or polyamide industrial quality adjustable
pitch high performance blades. The motors are threephase, 1,140 rpm and are of the heavy duty type complete
with permanently lubricated ball bearings, inherent threephase protection and NEMA Class B insulation.
Motor shafts are coated for rust protection. Each motor
is mounted on a heavy duty bracket which is constructed
of heavy gauge steel. Fan guards are furnished on the top
for safety purposes. Fan guards are constructed of heavy
gauge close meshed steel wire. The fan outlet venturi is
constructed of galvanized steel. The condenser fan motors
are cycled to provide head pressure control down to 50°F
[10°C] ambient.
gaskets do not require renewing at every maintenance
operation. However, if the head gasket is physically disfigured or deteriorated in any way, the system will require
new gaskets in order to retain the water-tight seal.
Periodically plate and coaxial heat exchangers should
be chemically cleaned to ensure optimum condenser efficiency. Frequency of cleaning will depend on individual
water conditions hence a suitable cleaning schedule
should be arranged based on experience and knowledge
of the building or local water supply loop.
Condenser Coils, Air Cooled
Condenser coils may be constructed of aluminum or copper fins that are mechanically bonded to copper tubes or
alternately may be constructed of high performance aluminum microchannel tubes, fins and manifolds that have
been brazed to form a complete refrigerant-to-air heat exchanger coil. An integral liquid sub-cooler circuit designed
for 10°F [5.6°C] subcooling is also provided to minimize
the possibility of liquid flashing while maximizing the cooling capacity of the system.
Evaporator Section
The direct expansion coil is constructed of seamless copper tubing expanded into full collared aluminum fins. The
tubes are arranged for a counter flow circuit and staggered to provide maximum heat transfer. A pressure type
distributor with hot gas inlet port and a heavy duty copper
suction header are included. Additional refrigerant circuit
components include thermostatic expansion valves with external equalizer and insulated suction lines in the airstream.
Components of a Direct Expansion (Dx) System
The evaporator is that part of the low pressure side of the
refrigerant system in which the liquid refrigerant boils or
evaporates, absorbing heat as it changes into a vapor.
Distributor
Condensers, Water Cooled
Water cooled units may contain either plate, shell and
tube and coaxial water cooled condenser. Water source
heat pump units may contain either plate and coaxial
water cooled condenser/evaporator.
Periodically tubes in the shell and tube condenser should
be mechanically cleaned to ensure optimum condenser
efficiency. Cleaning brushes are available from most refrigeration supply outlets. For better results, always remove
both heads before cleaning water tubes. Note that head
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Liquid line
Hot gas bypass line
Suction line
Expansion valve
Evaporator coil
Check valve on remote condensing
application (optional)
Figure 23: Direct expansion (Dx) coil
Thermostatic Expansion Valve
The Thermostatic expansion valve (TXV) is a precision
device designed to meter the flow of refrigerant into the
30
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
evaporator, thereby preventing the return of liquid refrigerant to the compressor. By being responsive to the temperature of the refrigerant gas leaving the evaporator and
the pressure in the evaporator, the thermostatic expansion
valve can control the refrigerant gas leaving the evaporator at a predetermined superheat.
P1
Bulb clamp
Remote clamp
Diaphram
P2
P3
External
equilizer
port
Figure 24: Thermostatic expansion valve (TXV)
Three forces that govern the operation of the TXV are: the
pressure created by the remote bulb and power assembly
(P1), the evaporator pressure (P2) and the equivalent pressure of the superheat spring (P3).
Dampers
Units from Venmar CES usually come with two sets of
dampers. However, units may have more than two sets if
the unit has been ordered with the recirculation or face
and bypass frost control options. Outside air dampers and
return air dampers can be motorized or gravity activated.
The following maintenance should occur in order to prevent the unit from working under too much pressure and
to prevent freezing issues.
Dampers must be kept free of foreign matter that might
impede normal free movement. Bearings between blades
and frames are made of polymer and require no maintenance. Note that the damper shafts do not need lubrication. All Venmar CES dampers and linkages are assembled
with non-lubricating bearings.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
•
•
•
•
Attachment mechanism linking motors to dampers
should be checked for tightness.
Damper jackshafts (if provided) are fitted with grease
nipples and should be lubricated once a year. Use a
premium quality lithium based grease conforming to
NLGI Grade 2 or 3 (examples are: Mobil – Mobilith
AW2, Chevron – Amolith #2, Texaco Premium RB,
Shell Alvania #2).
Dampers should be inspected for dirt; check the shaft,
arms, bars and controls rod every three months.
Inspect the seals to ensure none have pulled loose or
deteriorated. If a seal has been damaged, repair or
replace it with the same seal or same seal material.
Contact Venmar CES for replacement parts.
31
Belt Driven Fans
!
WARNING
Table 2: Wheel set screw torque in lb-ft
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
Set Screw Size
Diameter (Inches)
Belt driven fan, motor and drive assemblies should be
checked and inspected at regular intervals per the inspection list and procedures below. Listen for vibrations or
unusual sounds. Severe damage, premature failure and
loss of airflow can be avoided by regular inspection and
maintenance.
1. Check the fan, motor and bearing mounting bolts for
tightness according to the bolt torque chart in Table
1 below at time of start up, after 24 hours, then
every three months.
Size (Inches)
1/4­–20
1/4–28
5/16–18
5/16–24
3/8–16
3/8–24
7/16–14
7/16–20
1/2–13
1/2–20
9/16–12
9/16–18
5/8–11
5/8–18
3/4–10
3/4–16
7/8–9
7/8–14
1–8
1–14
Thread Designation Minimum Torque
UNC
6
UNF
7
UNC
14
UNF
16
UNC
24
UNF
28
UNC
42
UNF
45
UNC
69
UNF
83
UNC
99
UNF
118
UNC
150
UNF
176
UNC
254
UNF
301
UNC
358
UNF
422
UNC
500
UNF
602
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
lb-ft
75
6.2
5/16
144
12.0
3/8
252
21.0
7/16
396
33.0
1/2
600
50.0
5/8
1,164
97.0
3/4
2,016
168.0
7/8
3,204
267.0
1
4,800
400.0
3. Check each V-belt tension and adjust the motor base
for correct amount according to the deflection outlined in the Measuring Belt Tension procedure below
and in Appendix J for type of belt at time of start-up,
daily for the first week until they should acquire their
permanent set, then monthly. All belts should have
approximately the same amount of deflection. Be
aware of mismatched or worn belt sets. If a belt must
be changed, ensure to change all belts on the same
drive at the same time. Never replace just one belt
within a set.
Table 3: Bearing set screw torque in lb-in
Set Screw
Diameter
#10
Soft metric conversions are not acceptable for screw and hex sizes.
2. Check the fan wheel hub, bearings and drive sheaves
set screws for tightness according to the set screw
torque chart in Table 2 at time of start-up, after
24 hours of operation, monthly for the initial three
months then every three months. If wheel or bearing set screws have worked loose check the wheel
for any signs of movement (inlet space clearance
between the fan wheel and housing) or loose blades.
If Loctite was used on any set screws that have come
loose the set screws must be removed and cleaned
before re-tightening and Loctite must be re-applied.
lb-in
1/4
*Stainless steel set screws are not hardened and should not be
tightened to more than half the values shown.
Table 1: Minimum head bolt torque in lb-ft (Grade 5 bolts)
Carbon Steel Set Screw Torque*
Manufacturer
Link
Belt
40
Sealmaster
SKF
—
35
McGill Dodge
35
—
1/4
90
65
50
85
—
5/16
185
125
165
165
160
3/8
325
230
290
290
275
7/16
460
350
350
—
—
1/2
680
500
620
—
600
5/8
1,350
1,100
1,325
—
1,200
3/4
2,350
—
—
—
2,000
Split pillow block bearings are fixed to the shaft with tapered
sleeves and generally do not have set screws.
Measuring Belt Tension
a. Measure the belt span with a span scale.
b. Divide the belt span by 64 to determine the belt
deflection needed to check tension.
c. Set the O-ring on the span scale to the required
deflection value.
d. Set the small O-ring at zero on the force scale.
e. Place the scale end of the tension checker
squarely on one belt at the center of the belt
32
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
span. Apply force on the plunger until the bottom of the large O-ring is even with the top of
the next belt or until it is even with a straight
f. Read the force scale under the small O-ring to
determine the force required to give the needed
deflection.
g. Compare the force scale reading in Step F with
the correct value for the belt style and cross section. The force scale reading should be between
the minimum and maximum values shown in Appendix J.
h. If the deflection value is below the minimum,
tighten the belts. If the deflection value is above
the maximum, loosen the belts. The tension on
new belts should be checked during the first day
of operation, at the end of the first week and
monthly thereafter.
4. Check the fan and motor sheave alignment using a
straight edge along the outside edges of the sheaves
for equal sized fixed sheaves as shown in Figure 25
and Figure 26 at time of start-up, after 24 hours
of operation, monthly for the initial three months,
then every three months. When properly aligned,
the straight edge should touch the full face of both
sheaves. With one adjustable and one fixed sheave
with unequal sizes, use a string placed at the center
grove of both sheaves pulled tight to check alignment. Adjust sheaves for proper alignment and set
screws to proper torque.
Center lines
must coincide
5. Belt driven fan bearings are fitted with grease nipples
for lubrication. The grease quantity and lubrication interval depends on bearing (fan size) and rpm
and are indicated in the tables in Appendix L. Use a
premium quality lithium based grease conforming
to NLGI Grade 2 or 3 (examples are: Mobil Mobilith
AW2, Chevron Amolith #2, Texaco Premium RB,
Shell Alvania #2 or ESSO Beacon #325). Clean the
grease nipple first, then rotate the fan shaft slowly by
hand while adding grease. The lubrication intervals
are theoretical and will depend on site conditions,
hours of operation and temperature. It is recommended to make periodic inspections of the bearings
before these theoretical intervals.
6. Fan wheels, housings and drive assemblies should be
checked for dirt buildup annually and cleaned if necessary to keep them from becoming unbalanced and
to prevent loss of airflow. Clean with compressed
air to reduce any dirt, dust, lint or larger particulates that have bonded to the fan impeller housing
or drive assembly. Block dirt from entering the unit
and ductwork if necessary or remove fan assembly
from unit. Alternatively use low pressure steam, a
degreaser and rag. If a sheave requires cleaning, detergent and water can also be used. Ensure the belt
is dry before starting up the unit.
IMPORTANT
Be careful not to remove or dislodge balancing clips on
the fan blades while cleaning.
Lines must
be parallel
Fixed
sheave
Straight
edge
Adjustable
sheave
Figure 25: Equal sheave
size alignment
Figure 26: Unequal sheave
size alignment
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
33
FANWALL® Array
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
Maintenance Schedule
FANWALL array of multiple direct driven plenum fan and
motor “cubes” are equipped with permanently sealed
bearings and do not require lubrication. The following
maintenance schedule is recommended.
Monthly
•
Check the fan wheel to inlet cone alignment for possible noise from the wheel rubbing against the inlet
cone. See Fan Wheel/Cone Alignment below for instructions.
Every six months
•
•
Figure 28: Remove safety screen on motor end
3. Disconnect the four-wire electrical cable from the
motor junction box. Make note of wire locations for
reinstallation later. See Figure 29.
Check motor bearings for possible binding noise or
overheating.
Check fan wheels for dirt and grease accumulation.
Clean as necessary. Do not use any caustic cleaning
solutions.
Annually
•
Lightly lubricate damper and linkage bushings on
back draft dampers (if equipped).
Every Two Years
•
Examine fan housings and motor pedestal for corrosion. Clean and touch up with paint as necessary.
Figure 29: Remove electrical cable
4. Mark motor pedestal location on the motor pedestal
mounting angles (both sides), then loosen and remove (4) ½” bolts that retain the motor pedestal to
the mounting angles. See Figure 30.
Figure 27: FANWALL array
Fan Wheel and Motor Removal
1. Disconnect power to the fan array control panel
before maintenance. Follow all lockout and tag out
procedures.
2. Remove the optional safety screen (if provided) on
the motor end only of the cube in question by removing all four hex screws from the holding flange
that retains the safety screen. See Figure 28.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Figure 30: Remove motor pedestal retaining bolts
34
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
5. After removing the motor pedestal retaining bolts,
slide the motor/fan/pedestal assembly out to the
point where the motor lifting ring is clear of the cube
frame enough to use. If a mechanical device is available for use, attach it to the motor lifting ring. Lift
and remove the motor pedestal with motor and fan
wheel from the cube. The motor pedestal with motor
and fan wheel can be turned 180° and slid back into
the cube on the pedestal mounting angles or removed from unit for further disassembly.
6. Mark the location of the trans-torque bushing on the
shaft and the fan. To remove the fan wheel from the
motor shaft, remove the trans-torque bushing retaining hex nut using a 1” socket with a 12” extension by
turning counter clockwise. Loosen progressively until
the bushing is free from wheel hub and motor shaft.
Remove fan wheel/hub assembly. See Figure 31.
Figure 31: Mark location and remove trans-torque bushing
and fan wheel from motor.
7. If needed the motor may now be removed for service by
removing all (4) 3/8” motor retaining nuts and bolts.
Be sure to mark the motor base pattern and bolt
holes used on the motor pedestal. Rubber isolator
pads between the motor base and the pedestal are
optional and if supplied be sure not to lose them. See
Figure 32.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Figure 32: Remove motor retaining bolts; do not lose rubber isolator pads (if provided).
8. To reinstall the motor, fan wheel and fan wheel/
motor/pedestal assembly back into the cube, reverse
the steps above noting the following:
a. Insert the (4) 3/8” motor retaining bolts into the
holes in the motor pedestal from the underside;
make sure to use a standard washer on the bolt
side, install the rubber isolator pads (if supplied)
between the pedestal and motor base and only a
locknut is required on the motor side.
b. Square the motor on the pedestal according to
markings and tighten the bolts. With rubber isolator pads tighten the bolts to 20 ft-lbs. Without
rubber isolator pads tighten the bolts to 40 ft-lbs.
c. Install the fan wheel on the motor shaft with the hub
facing towards you. Line up the markings on the
hub/trans-torque bushing/shaft. Make sure that
the trans-torque bushing nut is flush to the hub.
Tighten the bushing nut progressively to 80 ft-lbs
turning clockwise.
9. Lift the motor pedestal with motor and fan wheel
(turn 180° if placed on the pedestal mounting angles
for disassembly) with the fan wheel inlet toward the
inlet cone. Place motor pedestal into the cube on the
pedestal mounting angles and slide the pedestal forward to the line that you previously marked. Line the
four pedestal bolt holes up with the bolt holes on the
mounting angles. Insert (4) ½” bolts into the holes,
make sure to use a standard washer on the bolt side
and a standard washer and lock washer on the nut
side. Hand tighten the bolts for now.
35
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
purpose of the damper is so that maintenance staff
can block the intake of a single fan to prevent back
flow until service on an inoperative assembly can be
performed. Note the directions of the damper blades
are running vertical. The damper is installed directly
onto the FANWALL® cube inlet side panel and over
the optional airflow straightener (if supplied).
Figure 33: Check fan wheel/cone alignment and overlap.
10. Check the inlet cone alignment to the fan wheel. Fan
wheel should not be rubbing against the fan inlet
cone when rotated by hand. The fan wheel to inlet
cone clearance should be approximately 1/16” gap
and the overlap should be as indicated in Appendix M for the fan wheel size. Adjust the overlap of
the wheel and cone by moving the motor pedestal
forward or back. Fan wheel should not be rubbing
on the inlet cone. If cone alignment is required see
instructions for Fan Wheel/Cone Alignment below.
Once alignment and overlap are correct, tighten the
(4) ½” pedestal mounting bolts to 90 ft-lbs.
11. Reconnect the four-wire electrical cable from the motor
junction box. Before operation, start the motor
slowly to ensure the fan rotation is correct. If the fan
wheel is not rotating correctly, check the motor leads
for proper installation.
a. Drive Side – Clockwise rotation when looking at
motor end
b. Inlet side – Counter-clockwise rotation looking at
fan inlet
IMPORTANT
Figure 34: Fan wheel/cone alignment – Step 2a
Figure 35: Fan wheel/cone alignment – Step 2b
3. If the optional airflow straighteners are furnished on
the inlet side of the fan it must be removed next. Remove all tek screws on the airflow straightener panel
frame and remove it from the cube.
Before restarting, re-balance the fan wheel once the
motor rotation and alignment have been corrected before placing the unit in operation.
Fan Wheel/Cone Alignment
1. To align fan wheel/cone, first disconnect power to
the fan array control panel. Follow all lockout and
tag out procedures.
2. If the optional backdraft damper is furnished on the inlet
side of the fan it must be removed first. Remove all
tek screws on all sides attaching the damper frame to
the inlet side panel and remove it from the cube. The
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Figure 36: Fan wheel/cone alignment – Step 3
36
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
7. Gently rotate the fan wheel to verify cone adjustment for
proper clearance from wheel.
4. Gently rotate the fan wheel to verify location of adjustment required.
Figure 40: Fan wheel/cone alignment – Step 7a and Step 9a
Figure 37: Fan wheel/cone alignment – Step 4
5. To make adjustment, loosen (do not remove) all the cone
retaining fasteners.
Figure 41: Fan wheel/cone alignment – Step 7b and Step 9b
8. Tighten all the cone retaining fasteners.
Figure 38: Fan wheel/cone alignment – Step 5
6. Using a rubber mallet, gently tap around the cone until
desired clearance is acquired between fan wheel and
inlet cone.
Figure 42: Fan wheel/cone alignment – Step 8
9. Once again gently rotate the fan wheel to verify cone
alignment.
10. To install the optional airflow straightener or backdraft damper reverse the steps above.
Figure 39: Fan wheel/cone alignment – Step 6
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
37
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
4. Place the blank-off plate over the optional airflow
straightener panel frame (if supplied) or onto the
matching “Z” frame and pre-drilled holes and fasten
together with or remove tek screws.
Blank-off Plate (if applicable)
1. Optional blank-off plate(s) are available so that maintenance staff can block the intake of a single fan to
prevent back flow until service on an inoperative assembly can be performed or it can be mounted on
spare FANWALL® cube(s) until they are required to be
put into service.
2. First disconnect power to the fan array control panel.
Follow all lockout and tag out procedures.
3. The blank-off plate is fitted to the inlet side of the
FANWALL cube on the optional airflow straightener panel frame (if supplied) or onto a matching
“Z” frame. There are 12 pre-drilled holes which are
located in the corners and middle of the airflow
straightener panel frame or “Z” frame matching
pre-drilled holes in the blank-off plate for fastening
together with tek screws.
Figure 44: Blank-off plate – Step 4
Figure 43: Blank-off plate – Step 3
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
38
Motors
!
•
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
•
Motors will operate effectively for years if they are kept
clean, dry and properly lubricated. An excessive running
current is a good indication of the overall condition of the
motor. Check the following items every six months (unless
otherwise indicated) for proper performance:
•
•
•
Motors must be cleaned with moderate air pressure
(around 25 to 30 psi). Dirt must be blown away from
vent fins and all other accessible areas. All areas surrounding the motor must be kept clear so air can
circulate freely to cool the motor.
Ensure all connections are secure. Look for loose
wires and loose contacts. Repair and tighten any defective connection.
Ensure the motor is operating at the current indicated on the nameplate. If not, a physical or electrical
restriction is working against the motor and it must
be repaired.
Ensure the motor is not vibrating too much. A significant vibration can come from a loose mounting bolt
or an unbalanced impeller. If significant vibration has
occurred, be sure to repair it and inspect the mounting base and the flexible duct connection for any
damage.
Motor lubrication must occur once a year when
grease nipples are provided with a premium quality
lithium based grease conforming to NLGI Grade 2 or
3 (examples are Mobile AW2, Chevron Amolith#2,
Texaco Premium RB, Shell Alvania #2 or ESSO Beacon
#325). Clean the grease nipple first, then rotate the
motor shaft slowly by hand while adding grease. Do
not over lubricate.
Filters
Standard 2” [51 mm] filters are disposable and should
be replaced every three months, sooner if pressure drop
across the filters is too great. High efficiency filters (optional) should be replaced when dirty. Use only in combination with 2” [51 mm] filters to protect them.
ing that should be given on the magnehelic gauge. The
data relative to accurate pressure drop across the filters is
available in the submittal. If the system is equipped with
both prefilters and final filters, it is recommended that prefilters be changed twice as often as final filters. Running a
unit with dirty and inefficient filters will lower the airflow
and thus lower the air quality of the area.
The tables in Appendix N provide data relative to the pressure drop across clean filters and indicate the type of read-
Coils
Dirt on the surface of the coil reduces its ability to transfer
heat which lowers the efficiency of the unit, resulting in
poor air quality and expensive operating costs. Because of
the condensate on the coil, the dirt often becomes wet
and contributes to the growth of microbial organisms.
Negligence in maintenance may result in serious health
related indoor air quality problems.
The coil should be kept clean for maximum performance.
To achieve maximum efficiency, clean the coil often during
periods of high demand or when dirty conditions prevail.
Venmar CES recommends cleaning the coil a minimum of
once per year to prevent dirt buildup in the coil fins where
it may not be visible.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
CAUTION
Do not use acidic chemical coil cleaners. Do not use alkaline chemical coil cleaners with a pH value greater than
8.5 or lower than 6 (after mixing) without using an aluminum corrosion inhibitor in the cleaning solution. Using
these types of cleaners may result in unit damage.
Coil fins can be cleaned by using steam with detergent,
hot water spray or a commercial chemical coil cleaner.
After cleaning the coil, be sure to rinse thoroughly.
39
!
WARNING
Many of the following steps need to be performed with
the unit powered off and locked out. Disconnect the
main power switch to the unit before performing service
and maintenance procedures.
Cleaning Procedure
1. Shut down the unit by closing the main disconnect at
the power inlet.
2. Open panels or doors to gain access to both sides of
the coil section.
3. Remove soft debris from both sides of the coil with a
soft brush.
4. Using a steam cleaning machine, clean the leaving
airside of the coil first (going downward) then clean
the entering airside. Use a block-off to prevent the
steam from penetrating a dry section of the unit.
5. Allow the unit to dry thoroughly before restoring
power.
6. Damaged coil fins (excluding brazed aluminum)
should be straightened by using a fin comb (not applicable to brazed aluminum heat exchangers).
7. Close all panels and doors once the coil is dry.
8. Restore electrical power to the unit.
Controls
General controls information regarding the navigation and
monitoring of your unit with the standard keypad, DDC
points list, ladder diagram and specific sequence of operation or required network communication is included in the
documentation in the control panel of your unit. Please
contact the factory if this information is missing or has
been lost.
Troubleshooting
See Appendix O for troubleshooting information. For
troubleshooting information on WSHP, compressors and
refrigeration circuits, see Appendix B; for gas-fired furnace
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
modules see Appendix D; and for electric heating coils, see
Appendix G.
40
Appendix A: Roofcurb Generic Assembly Instructions
2”
Wood nailer
Mineral wool
Mineral wool
2”
Standard design
Standard
design
With wood
nailer option
C
B
A
With wood
nailer option
Detail A
Detail C
Detail B
Figure A1: Roofcurb assembly – EnergyPack®, ERV5000–10000, HRV3000–10000 (outdoor units only)
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
41
Appendix B: Water Source Heat Pump (WSHP) Piping,
Installation, Maintenance and Troubleshooting
Units have the WSHP supply and return line connections
for each compressor condenser set piped to the outside
on the side of the casing as standard. An optional field cut
floor chase is available as an option, in which case the pipe
connections terminate inside the casing for each compressor condenser set. See the submittal drawings for number,
size, location, flow rate, type of fluid, pressure drop information and components included and factory installed for
the supply and return connections.
Water Piping Components Included
The following components are included and factory installed as standard, depending on the water conditions or
options selected.
1. A three-way modulating head pressure control valve
is included and factory installed in the compressor
compartment to maintain stable operation of the
refrigeration systems when operated on ground loop
water systems when the design inlet water temperature is below 65°F in the cooling mode. A refrigerant pressure transducer is also included and factory
installed in the compressor compartment on the
compressor discharge, which will modulate the water
flow to the condenser using a 2 to 10 VDC signal to
prevent the compressor discharge pressure from falling below the compressor operating limit.
2. A flow switch on the water return or leaving side of
the condenser is factory provided and installed in the
compressor compartment to monitor the presence or
absence of flow, which will shut down the compressor and unit if no flow is detected.
3. A water temperature sensor on the water return or
leaving side of the condenser is factory provided and
installed in the compressor compartment on 100%
water systems to monitor the water temperature,
which will shut down the compressor and unit for
freeze protection if the leaving water temperature
drops below 35°F.
4. An airside economizer coil, a three-way modulating
water economizer valve and a temperature sensor
are included with the WSHP WiSE coil option and
factory installed in the compressor compartment on
the water inlet or supply line and downstream of the
economizer coil for energy conservation. The water
temperature sensor is input to the DDC control system, which determines when to divert water to the
economizer coil for energy conservation in cooling
mode.
Water Piping Components Not Included
Vibration eliminators, manual or automatic shut-off valves,
pressure and temperature gauges, water strainer, vent
valves or air vents, flow measuring and balancing valves,
pressure relief valves or other safety or control piping requirements are not provided as standard and must be field
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
provided and installed outside of the unit. These components and installation are available as an option. See the
piping schematic and submittal drawings for information
on optional piping components when provided.
IMPORTANT
WSHP external water supply and return piping shall be in
accordance with National and Local Codes. Line sizing,
pressure limiting devices, back flow preventers, strainers,
valves, flow temperature and pressure measuring, freeze
protection, all other safety or control piping requirements
for system operation are the sole responsibility of the
Installing Contractor and/or Design Engineer. The water
supply must be sized for the maximum flow as indicated
on the submittals.
Recommended Piping, Components and
Installation
Recommended and required WSHP water line piping and
components with a detailed functional description are outlined below:
1. All WSHP should be connected to supply and return
piping in a two-pipe reverse return configuration. A
reverse return system is inherently self-balancing and
requires only trim balancing where multiple quantities of heat pumps with different flow and pressure
drop characteristics exist in the same loop.
2. The water line piping may be steel, copper or PVC.
Avoid dissimilar metal fittings as they may corrode.
The piping should be installed with a minimum number of bends and elevation changes for best performances. Size piping to minimize system pressure drop.
3. Water line piping should contain:
a. Short sections of high pressure flexible hose or vibration eliminators to reduce vibration and noise
transmission .One end of the hose should have
a swivel fitting to facilitate removal for service.
Hard piping connections are not recommended
due to the possibility of vibration that could damage piping connections, joints or transmit noise.
Where hard piping is used, unions should be
provided in the supply and return lines for service
and removal.
b. Manual shut-off valves in supply and return
water lines for isolation and service.
c. Pressure and temperature gauge connections in
the supply and return water lines to aid in startup and service.
d. A water strainer (16–20 mesh minimum) or some
means of removing foreign matter from the water.
e. Manual vent valves and/or automatic air vents at
the high points of the system in the supply and
return water lines to discharge non-condensable
42
f.
g.
h.
i.
air in order to avoid unexpected high head pressure and poor cooling/heating performance.
A flow balancing valve in the return water line to
set the required flow rate.
A flow measuring valve or pressure gauge/connections in the return water line to measure the
required flow rate.
A two-way motorized on/off water shut-off valve
to isolate water flowing through both the economizer coil (if equipped) and water-to-refrigerant
condenser for conservation when the unit is off.
The motorized water valve must open 90 seconds
prior to compressor start-up and remain open
five seconds after the compressor is shut off.
A relief valve in the water supply or inlet line if
the maximum pressure of components is less
than the water supply pressure to prevent damage, injury or death due to instantaneous release
of high pressure water.
!
6.
7.
8.
WARNING
To prevent injury or death due to instantaneous release
of high pressure water, provide relief valves on system
water piping. This will also help prevent water pump
damage or stoppage due to excessive system pressure.
4. WSHP should not be connected to the incoming supply and return piping until the water supply system
has been cleaned and flushed completely. After the
cleaning and flushing has taken place, the initial connection should have all valves wide open in preparation for the water system flushing.
5. Automatic flow controlled devices must not be installed
prior to system cleaning and flushing.
Cleaning and Flushing
1. Prior to first operation of the WSHP, the water circulation system must be cleaned and flushed of all construction dirt and debris by the Installing Contractor.
2. Short circuit connect the incoming supply line to the
outgoing return line, prior to the factory installed
piping at each connection point, before flushing to
prevent the introduction of dirt into the unit from the
supply line completed on site. This will prevent the
introduction of dirt into the unit.
3. Fill the system at the city water make-up connection
with all air vents open. After filling, close all air vents.
4. Start the main circulator with the pressure reducing
valve open. Check vents in sequence to bleed off any
trapped air to provide circulation through all components of the system.
5. While circulating water, check and repair any leaks
in the piping. Drains at the lowest point(s) in the system should be opened for the initial flush and blow
down, making sure city water fill valves are set to
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
9.
make-up water at the same rate. Check the pressure
gauge at the pump suction and manually adjust the
make-up to hold the same positive steady pressure
both before and after opening the drain valves. Flush
should continue for at least two hours or longer until
clean drain water is visible.
Shut off the circulator pump and open all drains and
vents to completely drain down the system. Short
circuited supply and return lines coming to the unit
should now be removed and supply and return lines
connected to the unit supply and return connections.
Do not use sealers at the swivel flare connections of
the hose(s).
Install any automatic flow controlled devices that
were removed for flushing.
Refill the system with clean water. Test the water
using litmus paper for acidity, and treat as required
to leave the water slightly alkaline (pH 7.5 to 8.5).
Note that during equipment functional testing, the
factory utilizes a mixture of 50% propylene glycol
and 50% water. Traces of propylene glycol/water
mixture may still be present in the equipment water
system and may require a complete water system
flush in 100% critical water applications. The specified percentage of antifreeze may also be added at
this time. Use commercial grade antifreeze designed
for HVAC systems only. Do not use automotive grade
antifreeze.
Once the system has been filled with clean water and
antifreeze (if used), precaution should be taken to
protect the system for dirty water conditions. Dirty
water will result in system wide degradation of performance and solids may clog valves, strainers, flow
regulators, etc. Additionally, the heat exchangers
may become clogged which reduces compressor service life or causes premature failure.
CAUTION
Units with WSHP installed outdoors must be protected
from freezing temperatures to prevent severe damage to
components.
10. Start the circulation pumps. After full flow has been
established though all components, air vented, lines
checked for leaks and loop temperatures stabilized,
the WSHP will be ready for check, start-up and water
balancing.
General Maintenance
Recording of performance measurements of volts, amps,
and water temperature difference (both heating and cooling) is recommended. A comparison of logged data with
start-up and other annual data is useful as an indicator of
general equipment condition.
43
Periodic lockouts almost always are caused by air or water
problems. The lockout (shut down) of the unit is a normal
protective result. Check for dirt in the water system, water
flow rates, water temperatures, airflow rates (may be dirty
filters), and air temperatures. If the lockout occurs in the
morning following a return from the night setback, entering air below machine limits may be the cause.
Water treatment is important for proper condenser operation. More frequent cleaning will be necessary if water is
not properly treated. For water treatment instruction, consult your local water treatment specialist.
WSHP units are designed for failsafe to heating.
Monthly
•
Check condenser coil for scaling.
Quarterly
•
Check oil level in compressor (half site glass).
Semi-annually
•
•
•
Check operation of crank case heaters.
Check for broken or loose pipe clamps.
Check moisture indicator of refrigerant site glass. A
‘Caution’ or ‘Wet’ condition requires changing filter
drier. If ‘Wet’ condition does not improve, it will be
necessary to evacuate system.
Yearly
•
•
•
•
Look for any sign of oil on all refrigeration components including coils, compressors, controls, tubing,
etc. Oil would indicate a refrigerant leak.
Check water lines for leaks.
Check expansion valve bulb (properly attached to
suction line, properly isolated).
Check the condensate drain pan and clean and flush
as required.
Troubleshooting
Lubrication
R410a should be used only with polyolester (POE) oil. The
HFC refrigerant components in R410a will not be compatible with mineral oil or alkylbenzene lubricants. R410a
systems will be charged with the OEM recommended lubricant, ready for use with R410a.
Charging
Due to the zeotropic nature of R410a, it should be
charged as a liquid. In situations where vapor is normally
charged into a system, a valve should be installed in the
charging line to flash the liquid to vapor while charging.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
CAUTION
It is very important to make certain that the recycle or recovery equipment used is designed for R410a. The pressure of R410a refrigerant is approximately 60% greater
than that of R22. Pressure gauges require a range up to
800 psig high side and 250 psig low side. Recovery cylinders require a 400 psig rating.
IMPORTANT
Filter driers must be replaced each time a system is open
to atmosphere (i.e. for a defective component replacement, refrigerant leak, etc.).
Compressor burnout
When a motor burnout occurs in a compressor, the resulting high temperature arc causes a portion of the refrigerant/oil mixture to break down into carbonaceous sludge,
corrosive acid and water.
Such contamination resulting from a burnout can result
in repeat failures if the contaminants are allowed to reach
and remain in the crank case of the replacement compressor. This situation can be prevented by following proper
cleanup procedures after a burnout.
To determine if a compressor burnout has actually occurred, run the proper electrical tests. This requires an accurate VOM Meter.
1. With all wires removed from the compressor terminals,
measure resistance from each terminal to the compressor casing. If any terminal shows a direct ground
(zero resistance), a failure has occurred. If not, continue.
2. With all wires removed from the compressor terminals,
measure resistance from each compressor terminal.
They should read the same. If two or more terminals
show zero resistance between them, the compressor
motor has failed (for actual resistance value, refer to
the respective compressor manual or contact the service department at Venmar CES).
3. If Steps 1 and 2 have not clearly identified a compressor failure, it will be necessary to meg the compressor
motor (refer to the respective compressor manual or
contact the service department at Venmar CES).
Compressor Burnout – System Cleanup
Any maintenance requiring refrigerant evacuation must be
performed using proper recovery procedures.
1. In order to avoid losing refrigerant to the atmosphere, recover refrigerant using standard recovery
procedures and equipment. Remove the inoperative
compressor and install the replacement.
2. Since the normal color of refrigerant oil varies from oil
to oil, take a sample of oil from the replacement
compressor and seal in a small glass bottle for com44
filter drier for a minimum of two hours. If the pressure drop exceeds the maximum limits for a temporary installation, replace the filter drier and restart the
system (see literature from filter drier’s manufacturer
for pressure drop maximum limits).
6. After the completion of Step 5, allow the unit to
operate for 48 hours. Check the odour (warning –
smell cautiously) and compare the color of the oil
with the sample taken in Step 2. Use of an Acid Test
Kit is recommended to test for acid content. If the
oil is discolored, has an acid odour, is acidic, or if the
moisture indicator indicates a high moisture content
in the system, change the filter driers. The compressor oil can be changed if considered desirable. Allow
the system to operate for an additional four hours
and recheck as before. Repeat until the oil remains
clean, odour and acid free and the color approaches
that of the original sample.
7. Replace the liquid line filter drier with one of the
normally recommended size. Remove the suction line
filter drier.
8. After the cleaning procedure is completed, re-check
in approximately two weeks to ensure that the system
condition and operation is completely satisfactory.
parison purposes after the cleaning operation is complete. Suitable 2 ounce bottles are available at any
drug store.
!
WARNING
To prevent injury or death due to instantaneous release
of high pressure water, provide relief valves on system
water piping. This will also help prevent water pump
damage or stoppage due to excessive system pressure.
3. Inspect all system controls such as expansion valves,
solenoid valves, check valves, reversing valves, contactors, etc. Clean or replace if necessary, remove all
installed filter driers.
IMPORTANT
Before starting the new compressor, replace any questionable component.
4. Install the recommended size suction line filter drier
and new size liquid line filter drier. Evacuate system
using the triple evacuation method. Re-charge the
system with new refrigerant (do not use the recovered refrigerant). See unit’s nameplate for proper
refrigerant charge.
5. Start the compressor and put the system in operation. As the contaminants in the system are filtered
out, the pressure drop across the suction line filter
drier will increase. Observe the differential across the
Table B1: Troubleshooting Refrigeration Circuit
Symptom
Head
Pressure
Suction
Pressure
Compressor
Superheat
Amp Draw
Subcooling
Water
Air
(Loops)
Safety
Temperature
Temperature Lockout
Differential
Differential
Undercharged system (possible leak)
Low
Low
Low
High
Low
Low
Overcharged system High
High
High
Normal
High
Low airflow heating High
High
High
Low airflow cooling Low
Low
Low
Low water flow
heating
Low water flow
cooling
Low
Low
Normal
Normal
High
Normal
Low
Normal
Normal
Low
Low
Low pressure
Normal
High pressure
High pressure
Low
High
Low
Low
Low
Low
Low
Low
High
Low
High
Low
temperature
Low
temperature
High
High
High
High
Low
Low
High
High airflow heating Low
Low
Low
Low
High
Low
Low
High airflow cooling Low
High water flow
Normal
heating
High water flow
Low
cooling
High
Normal
High
Low
Low
Normal
Low
temperature
High pressure
Low
Low
Low
Normal
Normal
Low
High pressure
Low
Low
Low
High
Normal
Low
Low
temperature
High
High
Low
Low
TXV restricted
High
Low
Normal
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Low
High pressure
45
Table B2: Performance Troubleshooting
Performance
Troubleshooting
Insufficient capacity.
Heating Cooling Possible Cause
x
x
x
Reduced or no airflow.
x
x
Leaky ductwork.
x
x
Low refrigerant charge.
Replace or clean.
Check for dirty air filter and clean or replace. Check
fan motor operation and airflow restriction. Too high
of external static. Check static vs. blower performance
curve.
Check for dirty air filter and clean or replace. Check
fan motor operation and airflow restriction. Too high
of external static. Check static vs. blower performance
curve.
Check supply and return air temperature at the unit
and at the distant duct registers. If significantly different, duct leaks are present.
Check superheat and subcooling; adjust charge.
x
x
Restricted metering device.
Check superheat and subcooling; replace TXV.
x
Defective reversing valve.
Perform reversing valve touch test.
x
x
x
x
x
x
Unit undersized.
Re-check loads and sizing.
Scaling in waterside heat
Perform scaling check and clean if necessary.
exchanger.
Inlet water too hot or too cold. Check load, loop sizing, loop backfill, ground moisture.
Check for dirty air filter and clean or replace. Check
fan motor operation and airflow restriction. Too high
Reduced or no airflow.
of external static. Check static vs. blower performance
curve.
Check pump operation or valve operation/setting.
Reduced or no water flow.
Check water flow. Adjust to proper flow rate.
Inlet water too hot.
Check load, loop sizing, loop backfill, ground moisture.
x
Not cooling or heating
properly.
Unit does not operate
in cooling.
Reduced or no airflow.
x
x
High head pressure.
x
x
x
x
Air temperature out of range.
Scaling in waterside heat
exchanger.
Unit overcharged.
x
x
Non-condensable in system.
x
x
x
Low suction pressure.
x
x
x
Low discharge air temperature in heating.
Dirty filter.
Solution
x
Bring return air temperature within design parameters.
Perform scaling check and clean if necessary.
Check superheat and subcooling.
Vacuum system, re-weigh in charge.
Check pump operation or valve operation/setting.
Reduced water flow.
Check water flow. Adjust to proper flow rate.
Water temperature out of range. Bring water temperature within design parameters.
Check for dirty air filter and clean or replace. Check
fan motor operation and airflow restriction. Too high
Reduced airflow in cooling.
of external static. Check static vs. blower performance
curve.
Air temperature out of range. Bring entering air temperature within design parameters.
Insufficient charge.
Check for refrigerant leaks.
x
Too high of airflow.
Check fan’s motor speed selection and airflow.
x
Poor performance.
See insufficient capacity.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
46
Appendix C: Positive and Negative Pressure Trapping
Removable plug
Cleanout
X
K
H
L
K
H
X
L
=
=
=
=
Minimum 0.5” [13 mm]
0.5” [13 mm] + maximum total static pressure
3.9375” [100 mm] if unit has a 6” [152 mm] tubular steel base
H + K + pipe diameter + insulation − X
Figure C1: Positive pressure trapping
Removable plug
Cleanout
H
J
X
L
=
=
=
=
X
H
L
J
1” [36 mm] (for each 1“ [25 mm] of maximum negative static pressure) + 1” [25 mm]
Half of H
3.9375” [100 mm] if unit has a 6” [152 mm] tubular steel base
H + J + pipe diameter + insulation − X
Figure C2: Negative pressure trapping
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
47
Appendix D: Gas-fired Furnace Modules Installation and Maintenance
Tubular Gas-fired Duct Furnace Module
!
WARNING
Fire or explosion hazard
1. Failure to follow safety warnings exactly could cause
serious injury, death or property damage.
2. Be sure to read and understand the installation,
operating and maintenance instructions in this appendix thoroughly before installing or servicing this
equipment.
3. Improper installation, adjustment, alteration, service
or maintenance can cause serious injury, death or
property damage.
4. Do not store or use gasoline or other flammable
vapors or liquids in the vicinity of this or any other
appliance.
For your safety – What to do if you smell gas
1. Open windows if appliance is indoors.
2. Do not try to light any appliance.
3. Do not touch electrical switches or use any phone in
the building.
4. Extinguish any open flame.
5. Leave the building immediately.
6. Immediately call your gas supplier from a phone
remote from the building. Follow the gas supplier’s
instructions.
7. If you cannot reach your gas supplier, call the fire
department.
Installation and service
1. Installation and service must be performed by a
qualified installer, service agency or the gas supplier.
The furnace covered by this appendix is a component of
a “Listed” product, subject to the guidelines of application as designated by the Certifying Agency and outlined
in the appliance Manufacturer’s installation and operation
instructions.
The information provided in this appendix applies to the
furnace module, installed in the appliance and to its operation, maintenance and service. Refer to the appliance
Manufacturer’s instructions for information related to all
other components.
IMPORTANT
Combustion air intake and vent locations differ; see submittal drawings for actual locations.
Installation Requirements
1. Be sure that the unit is located with respect to building construction and other equipment to provide
ready access and clearance to access panels or doors
that must be opened to permit adjustment and servicing of the heating section. See the required clearances provided on the mechanical drawing.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
2. Do not install the appliance where it may be exposed
to potentially explosive or hazardous atmospheres
containing flammable vapors or combustible dust.
3. Do not locate the appliance in areas or near building
ventilators or exhausts where corrosive vapors (such
as chlorinated, halogenated or acidic or airborne substances containing silicone) are present in the atmosphere or can be mixed with combustion air entering
the furnace module.
4. Do not install the appliance in locations where flue
products can be drawn in the adjacent building
openings such as windows, fresh air intakes, etc.
5. The appliance is not certified or suitable for use in
drying or process applications. Units used in such
applications voids any warranty and Manufacturer
disclaims any responsibility for this appliance or application.
6. If any original wire supplied with the furnace must
be replaced, it must be replaced with wiring material
having a temperature rating of at least 104°F [90°C].
7. Provide necessary support for wiring in furnace vestibule. Wiring should not contact metal surfaces that
may be hot during furnace module operation.
Installation
IMPORTANT
All gas furnace installations must be in accordance with
the National Fuel Gas Code ANSA Z223.1 (NFPA 54) in
the United States, to the Gas Installation Code Can/CGA
B149 in Canada and all other applicable local codes and
ordinances. These requirements include but are not limited to:
1.
2.
3.
4.
Combustion air supply to the gas furnace
Venting of the products of combustion
Gas supply piping and connections
Unit location and clearances
Verify the following before placing the gas furnace into
service:
1. Gas supply provided matches the gas type marked
on the furnace module rating plate, the gas supply
line has been completed according to the Gas Supply, Piping and Connections section and has been
cleaned, drained and purged to the external manual
shut-off valve.
2. There is an adequate supply of air for the combustion
process for the furnace module according to the type
of installation.
3. There is a properly designed vent system connected
to the furnace module to convey the products of
combustion (flue gases) outdoors and are directed
away from any combustion air intakes according to
the installation.
48
Outdoor Installation
Air for Combustion
The furnace is power vented with a combustion air draft
inducer/blower and needs an ample supply of air for
proper and safe combustion of the fuel gas. Combustion
air inlet hoods are provided in the panel on the furnace
vestibule. Do not block or obstruct air openings to the
area where the appliance is installed. Provide at least 6
feet [1,829 mm] clearance to side of the appliance, where
the combustion air inlet or vent (flue) gas discharge is located, from walls, parapets or adjacent buildings or equipment. Do not locate appliance near building ventilators or
exhausts, or areas where corrosive chemical vapors can be
drawn into combustion air supply. Refer to appropriate installation codes for required clearances to combustion air
openings and flue gas (vent) outlets.
Venting
The venting system for outdoor appliances is a Category
III, with the vent products at positive pressure and up to
550°F [288°C]. Each furnace must be individually vented.
The venting system is designed for horizontal direct discharge to the exterior of the cabinet and provided with
factory built individual vertical exterior double wall vent
stacks that extend above the top of the appliance by a
minimum of 1 to 2 feet [302 to 604 mm], providing a
minimum 4 foot [1,016 mm] separation between flue gas
discharge and combustion air inlet. A ½” drain fitting is
provided in the bottom of the stack permitting condensate that may form to drain through. The vent stacks are
open at top but protected by ½” x ½” [12 x 12 mm] mesh
screens. The vent discharge opening should be located
to provide an unobstructed discharge to the outside (see
Figure D1).
Flue gas chimney
(standard on outdoor)
Flue gas flow
unobstructed
Comb
Blwr
AHU
cabinet
AHU
cabinet
Combustion air inlet hoods
Figure D1: Typical outdoor vertical venting
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Where sufficient height for proper vertical venting must
be greater or in jurisdictions requiring a greater separation
between flue gas discharge and combustion air inlet the
vent stacks provided with the unit must be replaced by
separate self-supported factory built closed chimneys or
vents complying with a recognized standard to Category
III with a 90° elbow and a field supplied transition. The
closed venting system must employ a drain line in the vent
chimney and an approved rainproof vent cap must be applied to the termination.
The proper vent pipe diameter must be used for each furnace to ensure proper venting of combustion products.
See Table D1 for required furnace vent size and submittal
for number of furnaces and Btuh input rating.
Indoor Installation
Air for Combustion
Locate appliance to ensure an adequate supply of fresh
air to replace air used in the combustion and ventilation
process of the furnace module. The appliance must be
installed in a location with adequate clearances to provide
for an adequate combustion air space, service and inspection and proper clearances from combustible construction.
The appliance must be located in such a manner that it
does not interfere with the circulation of air in the heated
space.
All fuel burning equipment must be supplied with air that
enters into the combustion process and is then vented
outdoors. Combustion air inlet hoods are provided in
the panel on the furnace vestibule. Sufficient air must
enter the appliance location to replace the air exhausted
through the vent system. Do not install appliance in a confined space without providing wall openings to and from
this space. If building construction is such that the normal
infiltration does not provide sufficient air for combustion and venting, outside air must be introduced. Install
air openings that provide a total free area in accordance
with following and to the National Fuel Gas Code Z223.1
(NFPA 54) in the US or in Canada, to the Can/CGA-B149
Installation Code:
1. Air from inside the building – Opening of 1 sq. inch
[645 mm2] per 1,000 Btuh [293 W] of input, but
never less than 100 sq. inch [0.06 m2].
2. Air from outside (ducted) – Opening of 1 sq. inch
[645 mm2] per 2,000 Btuh [586 W].
3. Air from outside (direct opening) – Opening of 1 sq.
inch [645 mm2] per 4,000 Btuh [1,172 W].
As an option, a combustion air opening of proper size can
be provided in the furnace enclosure and ducted directly
to outdoors. See Separated Combustion Air Intake System
for further details.
49
Each furnace must be connected to a venting system to
convey flue gases outside of the heated space. Refer to installation codes noted above for specific requirements for
the product type being installed.
The induced draft fan rectangular vent connection for
each furnace is factory fitted with a rectangular to round
transition and run to the side of the furnace vestibule.
Each furnace must be connected to a separate factory
built chimney or vent complying with a recognized standard or a masonry or concrete chimney lined with a material acceptable to the authority having jurisdiction.
7. Dampers must not be used in vent piping runs. Spillage of flue gases into the occupied space could result.
8. Vent connectors serving Category I heaters must not
be connected into any portion of a mechanical draft
system operating under positive pressure.
Exhaust vent
terminal
Roof line
B
¼” [6 mm] per
1 foot [305 mm]
Exhaust
Venting
A
The proper vent pipe diameter must be used for each furnace to ensure proper venting of combustion products.
See Table D1 for required furnace vent size and submittal
for number of furnaces and Btuh input rating.
Table D1: Furnace, Vent Connection Size and Vent Pipe
Diameter
Input Rating
Btuh [Watts]
100,000–125,000
[29,307–36,634]
200,000–400,000
[58,614–117,228]
Vent
Connection
Diameter
Vent Pipe
Diameter
5” [127 mm]
5” [127 mm]
6” [152 mm]
6” [152 mm]
Vertically Vented Furnaces (see Figure D2)
– Category I (per NFGC and ANSI Z21.13 is a
non-condensing appliance with negative vent
pressure)
1. Use single wall or double wall (Type B) vent pipe
diameters for the appropriate models. Use insulated
vent outdoors.
2. Maximize the height of the vertical run of vent pipe.
A minimum of 5 feet [1.5 m] of vertical pipe is required. The top of the vent pipe must extend at least
2 feet [0.61 m] above the highest point on the roof.
Use Listed Type B vent for external runs.
3. An approved weatherproof vent cap must be installed to the vent termination.
4. Horizontal runs must not exceed 75% of the vertical
height of the vent pipe, up to a maximum of 10 feet
[3 m]. Horizontal runs should be pitched upward ¼
inch per foot [21 mm/m] and should be supported at
3 foot [1 m] maximum intervals.
5. Design vent pipe runs to minimize the use of elbows.
Each 90° elbow is equivalent to 5 feet [1.5 m] of
straight vent pipe run.
6. Vent pipe should not be run through unheated
spaces. If such runs cannot be avoided, insulate vent
pipe to prevent condensation inside vent pipe. Insulation should be a minimum of ½” [12.7 mm] thick, foil
faced material suitable for temperatures up to 500°F.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Air inlet
Tee fitting with drip
leg and cleanout cap
A = 10” [3.05 m] maximum horizontal run
(not to exceed 75% of vertical run)
B = 2 ft [0.61 m]
Figure D2: Indoor vertical venting
Horizontally Vented Furnaces (see Figure D3)
– Category III (Per NFGC and ANSI Z21.13 is
positive vent pressure and non-condensing)
Pressures in Category III venting systems are positive and
therefore, care must be taken to avoid flue products from
entering the heated space. Use only vent materials and
components that are UL listed and approved for Category
III venting systems.
!
WARNING
Do not use Type B vent within a building on horizontally
vented indoor furnaces.
1. All vent pipe joints must be sealed to prevent leakage
into the heated space. Follow instruction provided
with approved venting materials used.
2. The total equivalent length of vent pipe must not exceed 50 feet [15.35 m]. Equivalent length is the total
length of straight sections, plus 5 feet [1.52 m] for
each 90° elbow and 2.5 feet [0.76 m] for each 45°
elbow.
3. The vent system must also be installed to prevent
collection of condensate. Pitch horizontal pipe runs
downward ¼ inch per foot [21 mm/m] toward the
outlet to permit condensate drainage. Insulate vent
pipe exposed to cold air or routed through unheated
areas. Insulate vent pipe runs longer than 10 feet [3
m]. Insulation should be a minimum of ½” [12 mm]
thick foil faced material suitable for temperatures up
to 500°F [288°C]. Maintain 6” [152 mm] clearance
between vent pipe and combustible materials.
4. A vent cap approved for horizontal venting must be
provided. Vent cap inlet diameter must be the same
50
as the required vent pipe diameter. The vent terminal must be at least 12” [305 mm] from the exterior
wall that it passes through to prevent degradation
of building material by flue gases. The vent terminal must be located at least 1 foot [305 mm] above
grade, or in snow areas, at least 3 feet [1 m] above
snow line to prevent blockage. Additionally, the vent
terminal must be installed with a minimum horizontal
clearance of 4 feet [1.2 m] from electric meters, gas
meters, regulators or relief equipment. Periodically
clean the screens in the vent terminal (where applicable).
IMPORTANT
Each furnace must have its own individual vent pipe and
terminal. Do not connect vent system from horizontally
vented units to other vent systems or a chimney.
5. Through the wall vents shall not terminate over public walkways, or over an area where condensate or
vapor could create a nuisance or hazard. Provide a
vent termination clearance to building or structure
features per Table D2.
Table D2: Vent Termination Clearances
Structure
Minimum Clearance
4 ft. [1.2 m] below
Door, window or gravity inlet
4 ft. [1.2 m] horizontally
Separated Combustion Air Intake Systems
On indoor units for operation with separated combustion
air intake systems, the burner section is in a reasonably
air-tight vestibule compartment, as these systems provide
combustion air from outside the heated space and vent
the products of combustion outdoors. No air openings are
to be made in the vestibule to maintain a reasonably airtight seal. Additionally the unit must include the following:
1. A suitable air-tight gasket on the vestibule door or
access panel.
2. An observation window in the door to permit observation of ignition and main burner flame during
operation and servicing.
3. A door or panel interlock switch to ensure that door
or panel is closed or in place during operation.
4. The induced draft fan rectangular vent connection
for each furnace is factory fitted with a rectangular
to round transition and run to the side of the furnace
vestibule.
5. A single combustion air inlet supply duct connection
is provided in the furnace vestibule for the number of
furnaces provided. See submittal drawings for location, size and number.
Proper installation of combustion air intake and flue gas
exhaust piping are essential to proper operation of the inshot gas burner module. See Figure D4 and Figure D5 for
recommended installation.
IMPORTANT
1 ft. [305 mm] above
Forced air inlet within 10 ft. [3 m] 3 ft. [0.91 m] above
Adjoining building or parapet
6 ft. [1.8 m]
Adjacent public walkways
7 ft. [2.1 m] above grade
Exterior wall
A = 12” minimum
Approved combustion supply air intake and exhaust flue
gas vent piping and terminals must be used between the
unit and outdoors for combustion supply air and exhaust
flue gas. The inlet and outlet terminals must be located in
the same outdoor pressure zone to provide for safe appliance operation.
6 ft. [1.8 m] min.
to wall or
adjoining building
Exhaust vent
Approved vent caps
Combustion air inlet
A
2.5 ft. [0.75 m] min.
Exhaust
12” [0.3 m] min.
Air inlet
Exhaust
Tee fitting
with drip leg
Pitch vent pipe
downward from
furnace ¼ inch
per foot
18” [0.46 m] min.
* (See note)
Tee with drip leg and
cleanout cap
Heating appliance
18” [0.46 m] min.
* Provides sufficient height to
exceed expected snow depth
Exhaust vent
terminal
Figure D4: Separated combustion – vertical venting
Figure D3: Indoor horizontal venting
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
51
5 ft. [1.5 m] min.
25 ft. [15.2 m] max.
equivalent length
Pitch pipes down ¼ in./ft [21 mm/m]
toward terminal caps to allow for
condensate drainage
Building overhang
3 ft. [0.9 m] min.
12” [0.3 m]
Exhaust vent
6 ft. [1.8 m]
min.
Combustion air inlet
18” [0.46 m]
min. @ CL
24”
[0.6 m]
Adjacent
building
3 ft. [0.9 m] min.
above grade
or expected
snow depth
Note: Be sure that the vent cap used for horizontal venting applications is approved for horizontal application.
Certain Manufacturer’s vent terminals are approved for vertical installation only.
Figure D5: Separated combustion – horizontal venting
Gas Supply, Piping and Connections
1. All gas piping must conform with local building
codes and ordinances or, in the absence of local
codes, with ANSI Z223.1 the National Fuel Gas Code
and NFPA 54 in the US. In Canada, installation must
be in accordance with Can/CGA B149.1 for natural
gas and B149.2 for propane units.
2. Gas piping must be sized for the total Btuh input of
the appliance serviced by a single supply line. Refer
to the number of furnace(s) and the total input of
their rating plate(s). Each furnace has a ¾” NPT
piping connection extended to the exterior of the
cabinet. The gas supply line feeding more than one
furnace must be checked for size relative to the connection at each furnace to maintain minimum required pressure to each furnace.
3. A drip leg (sediment trap) and a manual gas shut-off
valve must be field supplied and installed immediately
adjacent to the point where the gas supply line enters the cabinet. To facilitate servicing, installation of
a union is recommended (see Figure D6). The appliance must be isolated from the gas supply system by
closing its individual manual shut-off valve during any
pressure testing of the gas supply piping system at
test pressures greater than 13.5” w.c. [½ psi]. Always
use clean, scale-free pipe and malleable iron fittings,
and remove all cutting and threading debris prior to
connecting pipes. Firmly support the gas piping so
that it cannot be dislodged from its installed position.
Gas supply line
1
Manual gas
shut-off valve
Ground joint union
with brass seat
Gas supply line
To controls
3”
min.
Plugged 1/8” NPT test
gauge connection
Sediment trap
Figure D6: Union installation
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
4. For the furnace(s) to operate properly, the minimum
inlet gas supply pressure to each furnace for natural
gas operation is 5.0” w.c. and for propane (LP) gas is
11.0” w.c. with the furnace(s) operating. Maximum
inlet pressure for either gas is 13.5” w.c. [½ psi]. For
higher gas pressures, a separate field supplied and
installed high pressure regulator sized for the total
Btuh input is required to reduce pressure to within
minimum and maximum range. The high pressure
regulator used must include full internal relief or a
separate relief valve is required to prevent gas pressure exceeding the maximum 13.5” w.c. [½ psi] limit
to prevent damage to the furnace gas valve(s).
5. A 1/8” NPT tap is provided on the inlet of the gas
valve to each furnace. A fitting suitable for connection to a pressure gauge capable of measuring gas
pressure should be connected to each furnace. Check
gas inlet pressure at each furnace with all of the furnaces operating at the same time. See Figure D7.
Min. 5.0” w.c. natural gas
Min. 11.0” w.c. propane gas
Max. 13.5” w.c.
Gas
supply
Unit 1
Pressure
regulator
Unit 2
Unit 3
Figure D7: Gas piping line, regulator and over pressure relief valve must be sized to be within the minimum and maximum pressure ratings of all furnaces or appliances serviced.
!
WARNING
1. All field gas piping must be pressure/leak tested
prior to operation. Never use an open flame to
check for leaks. Use a soap solution or other leak
detecting solution for testing.
2. Gas pressure to appliance controls must never exceed 13.5” w.c. [½ psi].
!
WARNING
1. When pressure testing at ½ psi or less, close the manual shut-off valve on the appliance before testing.
2. When pressure testing gas supply line at ½ psi
or higher, close manual gas valve and disconnect
heater from supply line to be tested. Cap or plug
the supply line.
Airflow Considerations, Condensation and Full
Modulation Firing Rate Control
1. Airflow through the furnace is dependent on the
configuration. See the submittal drawing for airflow
configuration through the furnace.
a. For vertical downflow (see Figure D8). In this
configuration, condensate due to operation of
air conditioning system can form in the furnace
tubes and would drain through the open furnace
52
tubes near the base in the furnace control vestibule. A condensate drain pan should be field
provided for these applications. A condensate
drain fitting is provided in the flue box. Some
condensation may occur in the flue collector box
with 5:1 modulating control and a ¼” stainless
steel drain line is attached to the drain fitting and
extended through to the outside of the furnace
vestibule for each furnace.
b. For horizontal or down airflow through the furnace, condensate due to operation of air conditioning system can form in the furnace tubes
and would drain to the furnace flue box. A condensate drain fitting is provided in the flue box.
A ¼” stainless steel drain line is attached to the
drain fitting and extended through to the outside
of the furnace vestibule for each furnace.
2. Furnaces equipped with modulating control are capable of minimum input rates as low as 20%. Below
the minimum modulation rate the furnace will cycle
on and off to maintain the discharge air setpoint.
Consideration must be given to the vent conditions
and particularly the circulating airflow rates to ensure
that the operating air temperature rise is above the
dew point temperature of the flue gases in all applications and below the maximum allowable air temperature rise to limit the furnace tube temperature.
The selection software limits the furnace input to be
below the maximum temperature rise of 90°F [50°C]
and the discharge sensor limits the maximum supply
air leaving temperature. In the event of a heat recovery failure where the furnace design temperature rise
may be insufficient, the low limit function will shut
down the unit to reduce the possibility of condensation. Condensation of the flue gas is corrosive and
will result in shortened heat exchanger life and is not
permitted. The materials used for furnace tubes and
vent connectors are designed for non-condensing
operation during the heating cycle.
3. The heat capacity of the furnace is controlled by
the burner orifices and the gas manifold pressure.
The manifold pressure is factory set but should be
checked at the time of start-up as described below.
It is important not to change the design conditions
or airflow, to measure the minimum and maximum
temperature rise sufficiently far enough downstream
(where the temperature is uniform) and make the
proper adjustments.
!
WARNING
Operation of the furnace module at vent temperatures
below that specified for a Category III could result in
condensation during operating cycles causing premature
failure of the vent connections or heat exchanger and
hazardous operation. Operation of the furnace module
above the maximum air temperature rise could result in
excessive tube temperatures, premature failure and high
limit switch shut down.
Figure D8: Vertical airflow configuration
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
53
!
WARNING – FOR YOUR SAFETY
The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this
appliance is hazardous.
Operating and Safety Instructions
1. See Figure D8 for component locations.
2. This furnace module does not have a pilot. It is
equipped with a direct spark ignition device that automatically lights the gas burner. Do not try to light
burners by hand.
3. Before operating, leak test all gas piping up to heater
gas valve. Smell around the unit area for gas. Do not
attempt to place heater in operation until source of
gas leak is identified and corrected.
4. Use only hand force to push and turn the gas control
knob to the ‘On’ position. Never use tools. If knob
does not operate by hand, replace gas valve prior to
starting the unit. Forcing or attempting to repair the
gas valve may result in fire or explosion.
5. Do not attempt to operate unit if there is indication
that any part or control has been under water. Any
control or component that has been under water
must be replaced prior to trying to start the unit.
Start-up
1. Turn thermostat or temperature controller to its lowest setting.
2. Turn off gas supply at the manual shut-off valve.
3. Turn off power to the appliance at the disconnect
switch.
4. Remove access panel or open door to appliance vestibule housing the gas furnace.
5. Move gas control knob to ‘Off’ position. The furnace
module is provided with a supply air proving interlock
switch to ensure minimum supply airflow prior to
burner operation. Set the switch after ductwork has
been completed to open just below the minimum
supply airflow on the furnace rating plate.
6. Install a tapped fitting for attachment to a manometer (or other gauge suitable for 14” w.c.) in the inlet
pressure tap and for 10” w.c. in the manifold pressure tap.
7. Wait five minutes for any gas to clear out. If you
smell gas, see Step 2 above and correct leak. If you
do not smell gas or have corrected any leaks, go to
the next step.
8. Turn gas control knob to ‘On’ position.
9. Open all manual gas valves.
10. Turn power on at disconnect switch.
11. For start-up, temporarily set the DDC Control System
for heating and to its highest position to initiate call
for heat and maintain operation of furnace. Continue
start-up following the Sequence of Operation, LED
Flash Code Key and Trouble Shooting Guide for FenVCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
wal 35-61 Series Direct Ignition Control based on the
burner firing rate control (on/off, two-stage or full
modulation) and Troubleshooting Guide provided on
the furnace at the end of this appendix.
12. Check and adjust manifold pressure (see Figure D9).
a. The correct heat capacity of the furnace is controlled by the burner orifices and the gas manifold pressure. The manifold pressure is factory
set but should be checked at the time of start-up
as described below. For modulation control the
analog input signal could also be limited by the
control system depending on the airflow rate.
See Airflow Considerations, Condensation and
Full Modulation Firing Rate Control above.
b. For two-stage and full modulation control systems
manifold pressure should be 1.2” w.c. for natural gas and 3.5” w.c. for propane during the 90
second warm-up period. Adjust low regulator on
two-stage gas valve, if necessary. After 90 seconds, manifold pressure should increase to 3.5”
w.c. for natural gas and 10.5” w.c. for propane
within 30 to 45 seconds for two-stage units. For
modulating units, after 90 seconds, the manifold
pressure will vary depending on the analog input
signal. At 10 VDC, pressure should be 3.5” w.c.
for natural gas and 10.5” w.c. for propane; at 0
volts the manifold pressure should be 0.3” w.c.
for natural gas and 1.1” w.c. for propane.
c. For on/off units, the manifold pressure should
be 3.5” w.c. for natural gas and 10.5” w.c. for
propane.
Figure D9: Gas valve
13. Prior to completing the start-up, check the appearance of the main burner flame. See Figure D10 and
Figure D11 for flame characteristics of properly adjusted natural gas systems.
a. The burner flame should be predominantly blue
in color, well defined and centered at the tube
entry. Distorted flame, yellow tipping of natural
gas flame or a long yellow flame on propane,
may be caused by lint and dirt accumulation
inside burner or at burner ports, at air inlet be54
tween burner and manifold pipe, or debris in the
main burner orifice. Soft brush or vacuum clean
affected areas.
b. Poorly defined, substantially yellow flames or
flames that appear lazy indicate poor air supply
to burners or excessive burner input. Verify gas
supply type and manifold pressure with rating
plate.
c. Poor air supply can be caused by obstructions
or blockage in heat exchanger tubes or vent discharge pipe. Inspect and clean as necessary to
eliminate blockage. Vacuum any dirt or loose debris. Clean heat exchanger tubes with stiff brush.
Poor flame characteristics can also be caused by
undersized combustion air openings or flue gas
recirculation into combustion air supply. Increase
air opening size or re-direct flue products to prevent recirculation.
d. Reduced air delivery can also be the result of fan
blade slippage, dirt accumulation in the fan blade
or low voltage to draft inducer motor. Inspect
draft fan assembly and be sure fan blade is secure to motor shaft. Check line voltage to heater.
Shut Down
1.
2.
3.
4.
Set thermostat or controller to lowest setting.
Turn off electrical supply to unit at disconnect switch.
Turn off manual gas supply.
Disconnect manifold and inlet pressure taps and reinstall pipe plugs.
5. Replace vestibule access panel or close door.
Normal Operation
1. Turn on electrical supply to unit at disconnect switch.
2. Turn on manual gas supply.
3. Set thermostat or temperature controller to desired
temperature.
4. Information outlining the normal Sequence of Operation and Wiring Diagram for the control system
supplied with the furnace model is enclosed with this
instruction.
Multi-purpose meter
Use microamp scale
FC− FC+
Red (+)
Black (−)
Series 35-61 Module
Figure D12: Flame sensor current check
Figure D10: Burner flame at start-up 1.2” w.c. manifold
pressure draft inducer – high speed
Fenwal Series 35-6 Ignition Control
Fault Conditions and LED Key
LED steady on
1 Flash
2 Flashes
3 Flashes
Internal control fault
Combustion airflow fault
Flame with no call for heat
Ignition lockout
LED flashes on for ¼ second and off for ¼ second during
fault condition. Pause between fault codes is three seconds.
Service Checks
Figure D11: Burner flame at high fire 3.5” w.c. manifold
pressure draft inducer – high speed
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Flame current is the current which passes through the
flame from the sensor to ground. The minimum flame
current necessary to keep the system from lockout is 0.7
microamps. To measure flame current, connect analog DC
microammeter to the FC− and FC+ terminals per Figure
D12. Meter should read 0.7 uA or higher. If the meter
reads below 0 on scale, meter leads are reversed. Disconnect power and reconnect meter leads for proper polarity.
55
Security Device Operation
1. A combustion air pressure switch is provided as part
of the control system to verify airflow through draft
inducer by monitoring the difference in pressure
between the draft inducer and the atmosphere. If
sufficient negative pressure is not present, indicating
lack of proper air movement through furnace heat
exchanger, the switch opens shutting off gas supply
through the ignition control module. On furnaces
with two-speed draft inducer operation, a dual air
pressure switch is used, monitoring high and low
speed pressures. The air pressure switches have fixed
settings and are not adjustable.
2. The furnace is equipped with manual reset rollout
switch(es) in the event of burner flame rollout. The
switch will open on temperature rise and shut off gas
supply through the ignition control module. Flame
rollout can be caused by insufficient airflow for the
burner firing rate (high gas pressure), blockage of
the vent system or in the furnace heat exchanger.
The furnace should not be placed back in operation
until the cause of rollout condition is identified. The
rollout switch can be reset by pressing the button on
top of the switch.
3. The furnace is equipped with a fixed temperature
high limit switch mounted on the vestibule panel
that shuts off gas to the heater through the ignition
control module in the event of reduced circulating
airflow over the heat exchanger. Reduced airflow
can be caused by motor failure of the circulating air
blower, dirt, blockage or restriction of the air inlet
or outlet to the unit. The high limit switch will automatically reset when the temperature drops to 30°F
[16.7°C] below the setpoint. Determine the cause of
the reduced airflow and correct.
!
WARNING
A secure and effective functioning gas burner requires
sufficient combustion gas exhaust discharge. Disabling
a security device such as a pressure sensitive switch on a
gas device is dangerous and can be fatal. This can also
prevent proper functioning of the device and will result in
the guarantee being void. Do not attempt to disable the
pressure switch to place the heater in operation. Contact
a qualified service agency.
4. A circulating blower air proving pressure switch is
installed that breaks power to the burner circuit to
disable the furnace in the event of loss of circulating
airflow over the heat exchanger. Loss of airflow can
be caused by a motor failure, broken fan drive belt or
restriction of the air inlet or outlet to the unit. A loss
in circulating airflow, if not detected early, can cause
the furnace to cycle on high limit which can cause
overheating and damage to internal components.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
WARNING
!
The circulating blower air proving switch is adjustable
and must be set properly to avoid damage due to furnace
cycling on high limit.
Maintenance
Furnace Module Inspection
Turn off all electrical power to the unit before inspection
and servicing.
1. The furnace should be inspected annually by a qualified service agency. The condition of the burners,
heat exchanger, draft inducer, vent system, operating
controls and wiring should be determined. Check for
obvious signs of deterioration, accumulation of dirt
and debris and any heat or water related damage.
Any damaged or deteriorated parts should be replaced before the unit is put back into service.
CAUTION
If any of the original wiring needs to be replaced, it must
be replaced with wiring materials suitable for 105°C.
Label all wires prior to disconnection when servicing unit.
Wiring errors can cause improper or dangerous operation. Verify proper operation after servicing.
2. Clean burners, heat exchanger, draft inducer and
vent ducts. Periodically clean the screens in the vent
terminal (where applicable).
3. Check heat exchanger for cracks. If any are present,
replace heat exchanger before putting unit back into
service.
4. Check the attachment point of the furnace module
to the cabinet or ducts to verify that they are airtight.
5. Check the automatic gas valve to ensure that the gas
valve seat is not leaking.
Furnace Module Operation Check
1. Turn on power to the unit and set thermostat or heat
controller to call for heat, allowing furnace module
to operate.
2. Check for proper start-up and ignition as outlined in
the Start-up section.
3. Check the appearance of the burner flame (see Figure D10 and Figure D11).
4. Return thermostat or heat controller to normal setting.
5. Refer to the appliance manufacturer’s instructions
for annual maintenance procedures on the complete
unit.
Replacement Parts
Replacement parts for the gas-fired furnace module are
available through our Parts and Service Department at:
56
Venmar CES Inc.
1502 D Quebec Avenue
Saskatoon, SK S7K 1V7
Email: venmarservice@venmarces.com
Phone: 1-866-4-VENMAR (1-866-483-6627)
Fax: 1-800-667-3716
SN Sequence of Operation – On/off
Operation
Fenwal 35-61 Series Direct Ignition Control with
Two-stage Gas Valve
When system is powered up 24 VAC will be applied to the
ignition control (IC) terminals 24 VAC/R. The control will
reset, perform a self check routine, initiate full time flame
sensing, flash the diagnostic LED for up to four seconds
and enter the thermostat scan standby state.
Call for Heat
1. Thermostat (controller) closes on call for heat powering terminal T2.
2. 24 VAC to is supplied to IC terminal TH, provided
limit switch is in closed position.
3. The control will check that pressure switch contacts
are open (IC terminal PSW is not powered).
4. Combustion blower is then energized at high speed
through IC terminal IND.
5. When the air switch (APS-1) closes, a 15 second prepurge period begins.
6. At end of pre-purge period, the spark commences
and the gas valves (both first and second stage) are
energized for the trial for ignition period.
7. Burners ignite and cross light, operating at maximum
input rate (manifold pressure set at 3.3” to 3.5“ w.c.).
8. When flame is detected by flame sensor the spark is
shut off immediately and gas valve(s) and combustion blower remain energized.
9. During heating operation, the thermostat, pressure
switch and main burner flame are constantly monitored to assure proper system operation.
10. When the thermostat (controller) is satisfied and the
demand for heat ends, the main valves are de-energized immediately, the control senses loss of flame
and a 30 second post-purge occurs before de-energizing the combustion blower.
11. If flame is lost during an operational cycle, the control
will respond within 0.8 seconds. The spark will be
energized for a trial for ignition period to attempt to
relight burners and prove flame sensor. If flame is reestablished, normal operation resumes.
Ignition and Operational Failures During a Call for
Heat Result in Lockout of the Ignition Control
1. If the burners fail to light or carryover during a trial
for ignition, the control will attempt two additional
ignition trials. If no flame is present at the flame senVCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
sor within 10 seconds, the spark and gas valve will be
de-energized. A 15 second inter-purge period begins
and the combustion blower continues to run. After
the inter-purge period another ignition trial will take
place.
2. If burner fails to light or prove the flame sensor following the two additional trials the control will go
into lockout. The valve relay in the IC will be deenergized shutting of the gas valve immediately and
the combustion blower following a 30 second postpurge period.
Recovery from Lockout
1. If the thermostat is still calling for heat one hour after
a lockout occurs, the control will automatically reset
and initiate a call for heat sequence.
2. The ignition control may also be manually reset, by
turning the thermostat down and back up to previous temperature setting or removing power (24V) to
IC terminal 24VAC.
Fault Conditions and LED Key
LED Steady On
1 Flash
2 Flash
3 Flash
Internal control fault
Combustion airflow fault
Flame with no call for heat
Ignition lockout
LED flashes on for ¼ second and off for ¼ second during
fault condition. Pause between fault codes is three seconds.
1. If during the initial call for heat the air switch contacts are closed for 30 seconds without an output to
the combustion blower, an airflow fault occurs (one
LED flash) and control will remain in this mode.
2. If the airflow switch remains open (or a rollout switch
is open) for more than 30 seconds after the combustion blower output (IND) is energized, an airflow fault
occurs (one LED flash) and control will stay in this
mode with combustion blower on, waiting for airflow switch (or rollout) to close.
3. If the airflow signal is lost during operation, the control
immediately de-energizes the gas valve and maintains blower operation. If the call for heat remains
and proper airflow is not detected, airflow fault occurs (one LED flash). If proper airflow is detected at
any time, the normal sequence will begin with prepurge.
4. If the main valve fails to close properly at the end of a
heating cycle and a flame is maintained, the combustion blower will continue in operation. If the valve
does close completely later removing the flame signal, the blower will run for the post purge period and
shut off.
5. Refer to Table D3 for further LED code troubleshooting.
57
HF Sequence of Operation – Two-stage
Operation with 2 Speed Controller
Fenwal 35-61 Series Direct Ignition Control with
TR1 Timer Relay Control
When system is powered up 24 VAC will be applied to the
ignition control (IC) terminals 24 VAC/R and to the Timer
Relay Control (TR1). The ignition control will reset, perform
a self-check routine, initiate full time flame sensing, flash
the diagnostic LED for up to four seconds and enter the
thermostat scan standby state. The amber light on the TR1
will be lit indicating it is in the ready position.
Call for Heat
1. Thermostat (controller) (first stage or first and second
stage) closes on call for heat.
2. 24 VAC to is supplied to IC terminal TH, provided
limit switch is in closed position.
3. The control will check that pressure switch contacts
are open (IC terminal PSW is not powered).
4. Combustion blower is then energized at high speed.
5. When the air switch (APS1) closes, a 15 second prepurge period begins.
6. At end of pre-purge period, the spark commences
and the first and second stage gas valves are energized for the trial for ignition period.
7. Burners ignite and cross light, operating at maximum
input rate (manifold pressure 3.5” w.c.).
8. TR1 is powered (Terminal 7) simultaneously (SR LED lit)
and begins timing a 90 second warm-up period while
maintaining the combustion blower at high speed (FR
LED lit). The TR1 will maintain this mode of operation, regardless of status of thermostat second stage.
9. When flame is detected by flame sensor, the spark is
shut off immediately and gas valves and combustion
blower remain energized.
10. When the initial timer in TR1 times out, it defaults
the gas valve to low fire and the combustion blower
to low speed and returns control of the operating
mode to the temperature controller. The SR LED
turns off and the MR LED is lit.
11. If the controller is calling for second stage heat TR1
Terminal 6 is powered. After a short time delay (approximately 15 seconds), the system switches the
combustion blower to high speed (FR LED lit) and
the second stage gas valve at 3.5” w.c. manifold
pressure (CR LED lit), provided the high air pressure
switch (APS2) is proved.
12. During heating operation, the thermostat, pressure
switch and main burner flame are constantly monitored by the IC to assure proper system operation.
13. Operation continues on high fire until the second
stage thermostat is satisfied, opening the second
stage contact and de-energizes Terminal 6 on the
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
TR1, turning off the second stage gas valve and returning the combustion blower to low speed.
14. When the thermostat (controller) is satisfied and the
demand for heat ends, the first stage valve is de-energized immediately, the control senses loss of flame
and a 30 second post-purge occurs (at high speed)
before de-energizing the combustion blower.
Ignition and Operational Failures During a Call for
Heat Result in Lockout of the Ignition Control
1. If flame is lost during an operational cycle, the control will respond within 0.8 seconds. The spark will
be energized for a trial for ignition period to attempt
to relight burners and prove flame sensor. If flame is
re-established, normal operation resumes
2. If the burners fail to light or carryover during a trial
for ignition, the control will attempt two additional
ignition trials. If no flame is present at the flame sensor within 10 seconds, the spark and gas valve will be
de-energized. A 15 second inter-purge period begins
and the combustion blower continues to run. After
the inter-purge period another ignition trial will take
place.
3. If burner fails to light or prove the flame sensor following the two additional trials the control will go
into lockout. The valve relay in the IC will be deenergized shutting of the gas valve immediately and
the combustion blower following a 30 second postpurge period.
Recovery from Lockout
1. If the thermostat (controller) is still calling for heat one
hour after a lockout occurs, the control will automatically reset and initiate a call for heat sequence.
2. The ignition control may also be manually reset, by
turning the thermostat (controller) down and back
up to previous temperature setting or removing
power (24V) to IC terminal 24 VAC.
Fault Conditions and LED Key
LED Steady On
1 Flash
2 Flash
3 Flash
Internal control fault
Combustion airflow fault
Flame with no call for heat
Ignition lockout
LED flashes on for ¼ second, and off for ¼ second during
fault condition. Pause between fault codes is three seconds.
1. If during the initial call for heat the air switch contacts are closed for 30 seconds without an output to
the combustion blower, an airflow fault occurs (one
LED flash) and control will remain in this mode.
2. If the airflow switch remains open (or a rollout switch
is open) for more than 30 seconds after the combustion blower output (IND) is energized, an airflow fault
occurs (one LED flash) and control will stay in this
mode with combustion blower on, waiting for airflow switch (or rollout) to close.
58
3. If the airflow signal is lost during operation, the
control immediately de-energizes the gas valve and
maintains blower operation. If the call for heat remains and proper airflow is not detected, and airflow
fault occurs (one LED flash). If proper airflow is detected at any time, the normal sequence will begin
with pre-purge.
4. If the main valve fails to close properly at the end
of a heating cycle and a flame is maintained, the
combustion blower will continue in operation. If the
valve does close completely later removing the flame
signal, the blower will run for the post purge period
and shut off.
5. Refer to Table D3 for further LED code troubleshooting.
MH Sequence of Operation – 20–100%
Modulation with 2 Speed Controller
Fenwal 35-61 Series Direct Ignition Control,
TR1 Timer Relay Control and SC30 Modulation
Control
When system is powered up 24 VAC will be applied to the
ignition control (IC) terminals 24 VAC/R and to the Timer
Relay Control (TR1). The ignition control will reset, perform
a self-check routine, initiate full time flame sensing, flash
the diagnostic LED for up to four seconds and enter the
thermostat scan standby state. The amber light on the TR1
will be lit indicating it is in the ready position.
Call for Heat
1. Thermostat (heat enable) closes on call for heat.
2. 24 VAC to is supplied to IC terminal TH, provided
limit switch is in closed position.
3. The control will check that pressure switch contacts
are open (IC terminal PSW is not powered).
4. Combustion blower is then energized at high speed.
5. When the air switch (APS1) closes, a 15 second prepurge period begins.
6. At end of pre-purge period, the spark begins and the
first stage and second stage gas valves are energized
for the trial for ignition period.
7. TR1 is powered (Terminal 7) simultaneously (SR LED
lit) and begins timing a 90 second warm-up period
while maintaining the combustion blower at high
speed (FR LED lit) and powers the SC30. The SC30
will output 12 to 13 VDC to the modulating control
valve during the timing duration (90 seconds) of TR1,
regardless of the analog input signal to SC30 Terminals 7 and 8.
8. Burners ignite at an intermediate high fire condition
(manifold pressure 2.5” w.c. or higher; the SC30
control provides 12.5 to 13.0 VDC to modulating
valve) and cross light.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
9. When flame is detected by flame sensor, the spark
is shut off and gas valve(s) and combustion blower
remains energized.
10. When the initial timer in TR1 times out, it defaults
the gas valve to low fire and the combustion blower
to low speed and returns control of the operating
mode to the building temperature controller. The SR
LED turns off and the MR LED is lit.
11. If the controller is providing an analog signal between 0.5 and 5.3 VDC to the SC30 control, the
system will continue to run at low speed combustion
blower and with only the first stage valve open. The
modulating valve will be powered proportional to
the input voltage signal from the controller, and will
open or close changing the gas manifold pressure.
Manifold pressure will vary from 0.3–1.2“ w.c. operating in this mode.
12. If the signal increases above 5.3 VDC, the SC30 relay
closes powering Terminal 6 on the TR1 and starts a
second time delay of 15 seconds. At the end of this
time delay the fan switches to high speed (FR LED
lit) and the second stage gas valve opens (CR LED lit)
through the TR1 (Terminal 9) provided the high air
switch contacts are closed. The manifold pressure will
vary from 1.4–3.5” w.c. in this mode.
13. During heating operation, the thermostat, pressure
switch and main burner flame are constantly monitored by the IC to assure proper system operation.
14. Operation continues in the high fire mode until the
controller input signal to the SC30 control drops to
4.7 VDC. At this point the SC30 relay circuit opens
(SC30 terminal 5 has no output) de-energizing the
second stage valve and the TR1 switches the combustion blower to low speed operation. Low fire
modulation will continue as in Step 11.
15. When the thermostat (temperature controller) is satisfied and the demand for heat ends, the heat enable
contact opens and the first stage valve is de-energized immediately, the control senses loss of flame
and a 30 second post-purge occurs (at high speed)
before de-energizing the combustion blower.
Ignition and Operational Failures During a Call for
Heat Result in Lockout of the Ignition Control
1. If flame is lost during an operational cycle, the control will respond within 0.8 seconds. The spark will
be energized for a trial for ignition period to attempt
to relight burners and prove flame sensor. If flame is
re-established, normal operation resumes
2. If the burners fail to light or carryover during a trial
for ignition, the control will attempt two additional
ignition trials. If no flame is present at the flame sensor within 10 seconds, the spark and gas valve will be
de-energized. A 15 second inter-purge period begins
and the combustion blower continues to run. After
59
the inter-purge period another ignition trial will take
place.
3. If burner fails to light or prove the flame sensor following the two additional trials the control will go
into lockout. The valve relay in the IC will be deenergized shutting of the gas valve immediately and
the combustion blower following a 30 second postpurge period.
Recovery from Lockout
1. If the thermostat (controller) is still calling for heat
one hour after a lockout occurs, the control will automatically reset and initiate a call for heat sequence.
2. The ignition control may also be manually reset, by
turning the thermostat (controller) down and back
up to previous temperature setting or removing
power (24V) to IC terminal 24 VAC.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
IC Fault Conditions and LED Key
LED Steady On
1 Flash
2 Flash
3 Flash
Internal control fault
Combustion airflow fault
Flame with no call for heat
Ignition lockout
LED flashes on for ¼ second, and off for ¼ second during
fault condition. Pause between fault codes is three seconds.
Refer to Table D3 for further LED code troubleshooting.
60
Table D3: LED Code Troubleshooting
LED Code System
Description
Actions
Check for open fuse or circuit breaker.
No power
None
On call for heat, nothing happens.
Check for poor wiring connection.
to T1
Check for failed 24 volt transformer.
System fault. Repeated lockouts (five) during continuous call for
heat.
Check input voltage and inlet gas pressure during operation.
No
24 VAC across terminal 24 VAC/V2-Gnd when
Steady on
Check for condensate or blockage in air tube or pressure switch.
operation thermostat calling for heat.
Check for blocked vent condition or obstruction in heat exchanger tubes.
Control fault; replace ignition control.
Check for proper operation of circulating air supply system and
for air filter blockage.
Check manifold pressure when limit cools and closes. Natural
Open
Thermostat call for heat. No power across termigas 3.5” w.c./LP gas 10” w.c.
2 Flashes limit
nals V1/V2 on control.
switch
Low combustion blower air output. Flue gas temperature
exceeds 550°F. Inspect for debris accumulation, proper wheel
attachment, proper voltage to blower.
Check for short in wiring to pressure switch.
Pressure switch contacts in closed position for 30
Airflow
1 Flash
seconds with no output to combustion blower.
Check pressure switch for closed contacts (with leads disconnected).
fault
Remains in this mode with combustion blower off. Replace pressure switch.
Failed combustion blower.
Check connections and air tube from draft inducer to air switch
Open pressure switch or flame rollout switch
for leaks.
when inducer (IND terminal) is energized. If switch
Check rollout switch manual reset; depress reset.
Airflow
remains open for more than 30 seconds after com1 Flash
fault
Check supply tube from draft inducer housing to pressure
bustion blower is energized, control will remain in
switches for condensate; drain line and re-connect.
this mode with IND terminal (blower) energized.
Check pressure switch for condensate accumulation.
Replace pressure switch.
Check for voltage to gas valve with thermostat in ‘Off’ position. Valve should not be powered.
Flame
Flame sensor failure/flame present with no call for
2 Flashes
If valve is not energized, check for gas flow (manifold pressure
fault
heat.
reading greater than 0). If gas flow is present, turn off main
shut-off valve and replace gas valve.
Verify gas supply available and operation of gas valve – manifold pressure at start of ignition cycle. Check for power to valve
terminals Low and Com while spark is energized.
Is spark present? If no, check igniter for debris between electrodes,
cracked ceramic and check ignition wire for short to ground.
Check flame sensor wiring connections to electrode and conFailure to light or carryover. Loss of flame or flame trol and for any abrasions.
signal during ignition or operating cycle. Control
Check for cracked ceramic on flame sensor or grounded senFlashes
Lockout
will initiate up to three ignition re-trials before
sor rod.
lockout.
Verify that ample air supply and proper venting of flue gases
occurs during operating cycle.
Check for circulating air leaks into burner compartment during
operation.
Check for re-circulation of flue gases into combustion air supply.
If all conditions satisfactory, replace ignition control.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
61
IG Series Drum and Tube Gas-fired Duct Furnace Module
!
WARNING – FOR YOUR SAFETY
The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this
appliance is hazardous.
If you smell gas:
1.
2.
3.
4.
Open windows.
Do not touch electrical switches.
Extinguish any open flame.
Immediately call your gas supplier.
•
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, injury
or death. Read the Installation, Operating and Maintenance Instructions thoroughly before installing or
servicing this equipment.
Gas-fired appliances are not designed for use in
hazardous atmospheres containing flammable vapors or combustible dust, in atmospheres containing chlorinated or halogenated hydrocarbons, or in
applications with airborne silicone substances.
!
•
WARNING
Introduction
General
1. These manuals have been prepared to assist in the
installation, operation and maintenance of your duct
furnace. It is good practice to know as much as possible about your duct furnace before trying to install
or operate it. Read the contents carefully before
proceeding. Due to the custom nature of this duct
furnace, not all possibilities are addressed in this
manual. In cases where a special application is not
covered, the customer or installer can obtain information from a Venmar CES sales representative or
the factory.
Notes
1. Please disregard any information and/or data covering optional components not supplied with the duct
furnace.
2. Do not destroy or remove information from this instruction manual. Leave this instruction in the electrical enclosure of the duct furnace.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
!
WARNING
1. Provincial/state regulations require that service mechanics that work on combustion equipment must
be licensed.
2. Contact with moving parts can cause injury or property damage. Automatic control devices may start
the duct furnace without warning. To prevent accidental start-up, the maintenance personnel should
always lockout all power supplies before working
on the duct furnace. A duct furnace will often have
more than one power connection point; disconnect
all sources of power before servicing.
3. Refer to the rating plate for fuel input and supply
pressures.
4. Do not attempt to start the burner if the duct furnace is full of vapor or gas, or if the combustion
chamber is very hot.
5. Do not use gasoline, crank case oil or any oil containing gasoline for fuel.
6. Do not burn garbage or paper in this duct furnace.
Never leave paper or combustible material near the
duct furnace.
7. Shut off the manual fuel supply valve if the burner
is shut down for an extended period of time.
Warranty
Coverage and Terms
1. Venmar CES standard warranty applies, provided the
duct furnace has been connected in accordance with
these instructions and operated under normal conditions, Venmar CES will, at its option repair or replace
any defective component.
Exclusions
1. Except as herein expressly stated, Venmar CES does
not warrant this product in any manner. There are no
other expressed or implied warranties, including any
warranty of merchantability or fitness for a particular purpose. This warranty does not cover damage,
which occurs in transit, or resulting from alteration,
accident, misuse or abuse from failure to carry out
recommended normal maintenance. Any technician’s
travel and labour expenses, which result from claims
against this warranty, are the responsibility of the
purchaser. In addition, it does not cover any proximate, incidental or consequential damages resulting
from the failure of defective components workmanship. Venmar CES’ sole obligation and the purchaser’s exclusive remedy for breach of any warranty shall
be, at Venmar CES’ option, to repair or replace any
defective component.
62
2. Venmar CES warranty is void if:
a. The duct furnace is not installed by a qualified
heating contractor in accordance with provisions
of this service manual and safe practices.
b. The duct furnace was not subject to only normal
use in service and was misused, neglected, altered or otherwise damaged.
c. The duct furnace is allowed to operate during
building construction period.
d. The duct furnace is installed without proper
clearance to combustible materials or located in
a confined space without proper ventilation for
combustion.
e. The duct furnace is operated in atmospheres
containing flammable vapors, chlorinated or halogenated hydrocarbons.
f. The temperature rise across the duct furnace is in excess of that shown on the duct furnace rating plate.
g. The duct furnace was operated at any time outside its published capacity and/or with any other
fuel than prescribed.
h. Field wiring is not in accordance with the wiring
diagram furnished with the heater.
i. Any automatic controls were inoperative during
duct furnace operation.
j. Proper maintenance is not provided on a regular
basis as outlined.
k. The start-up report, which is in the envelope inside the control panel, is not returned.
Return Procedures
1. To return defective products under these warranty terms,
please contact your supplier or a Venmar CES customer service representative at 1-800-563-6695.
2. Products returned to the factory must first be authorized
and a return authorization number provided. Return
transfer must be prepaid.
Installation Instructions
!
WARNING
This duct furnace must be installed by a qualified, licensed
fitter in accordance with local building codes and the
current edition of CAN\CGA-B149 (1,2) for installation in
Canada and applicable provincial regulations for the class;
which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made. In the United States the duct furnace
should be installed in accordance with Z223.1 for the
installation of Gas Burning Appliances and Equipment.
Installation Clearances
1. The duct furnace is designed to be installed within an air
handler cabinet within the airstream with the duct
furnace burner wall forming part of the airstream
wall and with the burner and controls outside of the
airstream.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
2. Check that the duct furnace is installed in accordance
with the allowable clearances from unprotected combustibles as shown on the duct furnace nameplate.
The air handler enclosing the duct furnace in the airstream should have insulated walls, floor and ceiling.
3. For safety and service, the following minimum clearances and guidelines shall be observed:
Table D4: Minimum Clearance Requirements
Minimum Clearance
Clearance
from Combustible
Requirement
Construction
Top
6” [15.2 cm]
Minimum Clearance
for Accessibility
0
Burner side
24” [61 cm]
39” [100 cm]
Flue
Opposite
burner side
Front/back
18” [45.7 cm]
24” [61 cm]
6” [15.3 cm]
0
6” [15.3 cm]
Type of floor Non-combustible
24” [61 cm]
0
4. The National Electrical Code (NEC or CEC) requires a
minimum of 39” [1 m] service space between the face
of any electrical enclosure and any wall or obstruction.
5. Provide sufficient clearance to open doors, install piping and ducting, flame observation port, high limit
switch, control panel, main fan motor and all access
panels/doors.
General Installation
1. Safety considerations to determine if the duct furnace
is equipped with all of the safety devices required
for the particular application is the responsibility of
the air handler manufacturer. Safety considerations
include the accessibility of the equipment to nonservice personnel, the provision of electrical lockout
switches, maintenance procedures and automatic
control sequences.
2. Clearly identify all emergency shut-off devices.
3. The duct furnace must not be operated in the presence of chlorinated vapors. When such vapors mix
with the products of combustion, highly corrosive
compounds result, which will cause the premature
failure of the heat exchanger and other components.
4. Check that there are, or will be, no explosive, flammable or toxic vapors, or abnormal dust in the area
where the duct furnace is located or operated.
5. It is important to seal all connections to prevent air leakage and system performance problems. Provide
removable access panels on both the upstream and
downstream sides of the duct furnace in the air handler or ductwork. These openings shall be accessible
when the duct furnace is installed and shall be sized
to allow the observation of smoke or reflected light
inside the casing to indicate the presence of leaks in
63
the heat exchanger. The covers for the openings shall
be attached in such a manner as to prevent leaks.
6. Seal the perimeter of the duct furnace between the
outside casing and the inside of the air handler to
prevent air bypassing or leakage.
7. When the duct furnace is installed in an enclosed
heater room, it is imperative that the heater room
itself is not used as an air plenum. Ductwork must
be used for all supply and return air to and from the
duct furnace air handler, as well as any other fans,
which may be installed in the same room.
8. Particular attention should be given to service access
to all operating controls.
9. If air handlers are mounted indoors, ensure that any
exposed electrical controls and automatic gas ignition
control systems are not exposed to water spray, rain
or dripping water.
10. If air handlers are mounted outdoors, provide an enclosure to protect the burner and electrical controls
from the elements. This enclosure must be sealed
from the airstream and provided with air intakes for
combustion. Air intakes should be a minimum of 12”
[305 mm] from the base of the air handler to prevent
blockage by snow and be sized per Combustion Air
Requirements and Exhaust Stacks and Venting. If
the furnace is equipped with an induced draft fan,
increase air intakes by 25%. The enclosure access
must be sized to allow for easy access and removal of
the burner and controls. The enclosure venting must
be sized to prevent the ambient temperature from
exceeding 125°F [52°C] or the maximum rating for
components.
11. Check that the duct furnace is securely mounted, level
and braced and will not be subject to swaying or
movement, which would put a stress on electrical
connections.
Drains and Traps
1. Heat Exchanger Condensate – The duct furnace
is supplied with a condensation removal pipe
connection(s). Condensate from the heat exchanger
and stack is acidic (pH value approximately 3) and
may contain chemical compounds requiring special
drainage. Both indoor and outdoor units must have
the duct furnace condensate drain connections piped
to a sanitary sewer.
!
WARNING
Do not drain into the building or onto the roof.
Failure to connect the condensate drain to a sanitary
sewer can result in combustion gases entering the space,
uncontrolled water flow into the building or onto the
roof resulting in standing water or large amounts of ice
buildup, building damage, injury or death.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
The drain must be installed in accordance with all
plumbing codes. The condensate is to be drained via
½” PVC or steel pipe with an indirect connection to
the plumbing wastes.
K
H
For positive gas-fired furnaces (no induced draft exhaust)
K = Minimum 0.5” [13 mm]
H = Overfire pressure on furnace nameplate “w.c. + 1”
The water level would be 1“ above the top of the “U” of the trap
Figure D13: Condensate trap – positive gas-fired furnace
H
J
For negative gas-fired furnace (with induced draft exhauster)
H = Minimum 8.5” [216 mm]
J = Half of H or 4.25” [108 mm]
The water level would be 1” below the bottom of the entrance to the drain.
Figure D14: Condensate trap – negative gas-fired furnace
2. Since the condensate is drained by gravity, avoid long
runs of drain piping. If a long run of trapping cannot
be avoided or the piping has water flow restrictions
such as several elbows, add extra height to provide
enough hydrostatic head to overcome the frictional
losses. Always slope piping down a minimum of 1/8”
per foot [10 mm/m] in the direction of the flow.
IMPORTANT
Where a condensate neutralizer is used, an overflow shall
be provided such that condensate will be directed to
the drain in the event the neutralizer becomes plugged.
Indoor installations typically require a condensate trap
to be installed to prevent combustion gases entering the
space, see Figure D13 for sizing, positive pressure. Outdoor installations may require special attention to drains
to prevent freezing and clogging of the drain line.
3. The condensate drain line must include a condensate
trap to prevent combustion gases entering the sewer
on positive fired furnaces or sewer gases entering the
furnace on negative fired furnaces. The discharge of
64
the trap must be at atmospheric pressure and not
tied into a pressurized line or the trap will not function properly.
4. Never attach drain piping to a closed drain or sewer
gases may enter.
5. To function properly, a trap must always be primed.
The “U” portion of the trap must be full with water.
If the trap is not properly primed, air will be sucked
through the trap upon start-up and prevent condensate drainage on negative fired furnaces or combustion gases will be pushed into the sewer on positive
fired furnaces. Drains that are inactive will dry out
and not function properly. An open tee on the leaving side of the trap is recommended for filling the
trap with water and for maintenance.
IMPORTANT
Outdoor installations may require special attention to prevent freezing and clogging of the drain line. Insulate and
heat trace the condensate line portion that is outdoors.
Combustion Air Requirements
1. If the duct furnace is installed in furnace rooms, confined
areas or low leakage construction buildings, provisions must be made for combustion air. The heater
shall be located such that a negative pressure will not
be created, which will starve the burner of combustion air.
2. Air for combustion should be drawn and ducted
from outdoors where there is a possibility of exposure to substances such as:
• Chlorinated laundry products
• Carbon tetrachloride
• Permanent wave solutions
• Halogen-type refrigerants
• Chlorinated waxes and cleaners
• Cleaning solvents (perchloroethylene)
• Chlorine based pool chemicals
• Printing inks, paint removers, etc.
• Water softening chemicals
• Cements and glues
• De-icing salts or chemicals
• Anti-static fabric softeners
• Masonry acid washing materials
• Hydrochloric acid
3. In some cases, Local Authorities require that combustion air be ducted directly to the burner. Refer to the
relevant installation standards in the current CAN1B149 (1,2) in Canada and Z223.1 in USA. On outdoor air handlers air intakes should be a minimum of
12” [305 mm] from the base of the air handler. If the
duct furnace is equipped with an induced draft fan,
increase air intakes by 25%.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Exhaust Stacks and Venting
1. Installations must be in accordance with the requirements of authorities having jurisdiction or in the
absence of local codes, with the relevant installation
standards in the current CAN1-B149 (1,2) in Canada
and Z223.1 in USA. Local codes may supersede any
of the provisions in the above installation standards.
2. Distances from adjacent public walkways, adjacent
buildings, openable windows and building openings,
shall conform to these codes.
3. Flue outlets must be located so as to prevent blockage by snow.
4. Building materials must be protected from degradation by flue gases.
5. Flue outlets must have a minimum horizontal clearance from electric meters, gas meters, regulators and
relief equipment of 6 feet [1.83 m] to CAN1-B149.1
and B149.2 in Canada and 4 feet [1.22 m] to Z223.1
in USA.
6. Flue outlet pressure must not exceed rating on the
nameplate for maximum overfire pressure on positive
fired chambers or maintain the overfire draft pressure for the heater on negative fired chambers with
induced draft (ID) fans.
7. All horizontal runs should have a minimum rise of ¼”
per foot [21 mm/m] of horizontal run in the direction of
discharge to prevent the accumulation of condensate.
8. Stacks shall have means provided for the drainage of
condensate.
9. Refer to the rating plate for the category of appliance
to select the venting. Consult the authorities having
jurisdiction and use a gas-tight, water-tight venting
system constructed of material resistant to corrosion
by condensate.
10. Do not install dampers or other restrictive devices in
the flue vent pipe.
11. Stack terminations must be kept to approved distances from fresh air intakes, rooflines, etc. Guy wires
may be required to brace the stack above rooflines.
12. The stack should be installed in such a manner that
access to the duct furnace is not obstructed. Do not
support the weight of the stack on the flue connection of the duct furnace.
13. Approved methods must be followed when putting
the stack through walls, floors, roofs, etc.
14. The stack shall have a minimum of at least 18” [457
mm] clearance to combustible material.
15. A duct furnace, if installed in a building, full enclosure or in a location requiring that the vent be extended, shall be vented as prescribed by the authority
having jurisdiction.
16. The overfire draft measured with a manometer at the test
port in the burner compartment must be the same as
labeled ‘Overfire Draft’ or not exceed the ‘Maximum
65
Overfire Positive’ pressure ratings on the rating plate
of the duct furnace.
17. Power Venting Adjustment – The flue draft should be
adjusted at the damper of the induced draft (ID) fan
when the duct furnace is operating on high fire.
18. Gravity Venting Adjustment – The flue draft should
be adjusted at the damper of the burner fan when
the duct furnace is operating on high fire.
Gas Connections
1. Gas-fired duct furnace shall be installed in accordance with:
a. In Canada the Installation Codes CAN/CGA B149
(1,2) latest edition and applicable provincial regulations for the class of heater being installed. Authorities having jurisdiction should be consulted
before installations are made.
b. In the United States the National Fuel Gas Code,
ANSI Z223.1; for airplane hangers in accordance
with the Standard for Aircraft Hangers, ANSI/
NFPA 409; for public garages in accordance with
the Standard for Parking Structures, ANSI/NFPA
88A or the Standard for Repair Garages, ANSI/
NFPA 88B and applicable local codes for the
class of heater being installed. Authorities having
jurisdiction should be consulted prior to the commencement of work.
2. An emergency manual shut down valve should be provided upstream of the piping to the duct furnace
and labeled for quick identification. Color coding of
pipe may be required and is recommended. Check
the duct furnace rating plate for the fuel type, supply
pressure and input rating.
3. Gas supply pressures higher than 14” w.c. [3.5 kPa]
require an additional field installed high pressure
regulator. The high pressure regulator should have
an internal or separate relief valve to protect components to their maximum rated pressure limits. The
high pressure regulator and relief valve should, if
possible, be mounted at least 5 to 10 feet [1.52 to
3.04 m] upstream from the appliance regulator at
the duct furnace. Run the gas line to the duct furnace and mount these items so as not to interfere
with or hinder access to the duct furnace or any of
its components. Install a 1/8” NPT plugged tapping
connection immediately upstream of the gas supply
connection to the duct furnace for test gauge connection if the duct furnace is not so equipped.
4. The gas line to the duct furnace should be taken off
the top of the main gas line. A drip leg with screwed
cap should be installed at the bottom of the vertical
drop in the gas line to the duct furnace.
5. Vent the main gas appliance regulator and the pilot
regulator to atmosphere. Gas pressure switches, high
pressure regulator, high pressure relief valve and the
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
6.
7.
8.
9.
normally open vent valve (if any of these components
are supplied) must be vented to atmosphere separately from all other components. Vent lines should
terminate outside the building with a turndown
elbow and birdscreen. Vent lines must be sloped to a
condensate drip leg. Locate the drip leg ahead of the
item being vented to prevent any condensate that
may form from draining back into the vented item.
Bleed and vent lines shall be installed in accordance
with CAN/CGA B149 (1,2) latest edition or the National Fuel Gas Code, ANSI Z223.1.
See Gas Manifold Piping Drawing included with submittal drawings.
Gas piping must not be used to support, hang or
steady the duct furnace.
The duct furnace and its individual main manual
shut-off valve must be disconnected (in closed position) from the gas supply piping system during any
pressure testing of the gas supply piping system at
test pressures in excess of ½ psig [3.5 kPa].
Duct furnaces are certified for altitudes of 0 to 2,000
feet [0 to 610 m]. When a duct furnace is installed at
elevations above 2,000 feet the input rating shall be
reduced at the rate of 4%for each additional 1,000
feet [300 m], in accordance with standard CGA 2.17.
A separate label must be affixed next to the duct furnace nameplate indicating the adjustments as follows:
This appliance has been adjusted for use at an altitude of:
___________ feet________________ m
Adjusted maximum gas input:_________Btu/hr_________ kW
Adjusted manifold pressure:___________” w.c._________kPa
Date of adjustment:____________________________
Adjusted by:___________________________________
Electrical Connections
1. All electrical connections to the duct furnace and main
disconnect switch shall conform to local codes and:
a. In Canada the Canadian Electrical Code Part 1,
(CSA C22.1) and all local codes.
b. In the United States the National Electrical Code
ANSI/NFPA 70 and all local codes.
2. The correct power supply requirements are shown on
the duct furnace nameplate.
3. An electrical disconnect switch having adequate
ampacity (see duct furnace nameplate for voltage
and ampacity), if not provided as part of the duct furnace, shall be installed in accordance with Article 430
of the National Electrical Code, ANSI/NFPA 70.
4. The duct furnace must be electrically grounded.
5. Mount and wire all external controls to the duct furnace
(i.e. remote control panel, temperature controller,
interlocks with external electrical circuits or any other
auxiliary electrical item). Numbered terminals are pro66
vided in the remote control cabinet and on the junction box on the duct furnace for the connection of
these controls (see wiring diagram). Check inside the
control panel for labels indicating entry location(s) for
field installed wiring and control wiring.
6. Dotted lines on a wiring diagram indicate field wiring by
the Installer.
7. Solid lines on the wiring diagram indicate factory wiring
by the Manufacturer.
8. Fuses are furnished and installed in accordance with
the applicable Electrical Code. If replacement is necessary the original fuse amperage shall be adhered
to. Failure to do so may result in damage to the components within the electrical system.
9. If the duct furnace is to be installed to supply air to
an area where freeze-up protection is needed in the
event of burner shut down, then a low temperature
limit control is recommended.
10. When connecting a power supply to a three-phase
motor, take care that the three-phase wiring gives you
the correct motor and blower rotation on all motors.
11. Replacement wiring must be equivalent to original wire. See wiring diagram for requirements for
shielded or twisted wire.
12. If a space thermostat is used with the duct furnace,
locate the thermostat so that cold drafts and hot
discharge airstreams do not affect its performance.
Do not mount the thermostat on the casing on the
duct furnace or any other location where it may be
affected by radiated and conducted heat. Refer to the
instruction furnished with the thermostat for further
details.
Air Distribution and Throughput
1. The duct furnace is designed for constant airflow operation. An air proving interlock switch is provided to
ensure minimum airflow over the combustion chamber prior to burner operation. The range of airflow
and the pressure drops for each frame size are given
in the submittal drawings.
2. The duct furnace must be installed on the positive or
pressure side of the air circulating blower.
3. Allow the air circulating blower to run for a sufficient
period after the burner is shut down to cool off the
heat exchanger, approximately five minutes.
4. For multi-volume applications the burner input rate
must be restricted in proportion to the airflow rate so
the maximum design temperature rise and minimum
airflow is not exceeded.
5. The duct furnace must be installed with sufficient
upstream and downstream clearance to provide unobstructed and even airflow across the openings.
CAUTION
Failure to provide even airflow can cause overheating and
premature failure.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
IMPORTANT
Do not split or branch off leaving ducts or mount temperature sensors directly after the duct furnace allowing sufficient distance for air temperature to blend evenly. Allow
approximately two equivalent duct diameters. Equivalent
diameter = SQRT (4 AB/PI).
Duct Furnace Start-up and Operation
Precautions Before Starting the Duct Furnace
1. Provincial or state regulations frequently require that service mechanics that work on combustion equipment
must be licensed. Unqualified personnel should not
start the duct furnace.
2. Refer to the notes in the Introduction, at the beginning
of this manual before continuing.
!
WARNING
Do not attempt to start the burner if the duct furnace is full
of vapor or gas, or if the combustion chamber is very hot.
Start-up Checklist
IMPORTANT
When starting up the duct furnace for the first time or if
it has been shut down for an extended period of time the
same start-up procedures, as outlined in Start-up Checklist, Start-up Instructions and Restarting After Ignition
Failure should be followed.
1. Set the electrical disconnect in the ‘Off’ position.
2. Set all additional switches in the ‘Off’ position.
3. Close the main manual gas valve, pilot manual gas
valve, main and pilot manual firing valves.
4. Check the supply voltage. Voltage must be within
10% of nameplate rating. If not, consult the power
company and have the voltage condition corrected
before start-up.
5. Check all electrical connections on controls and in
the control cabinet. Tighten if necessary.
6. Check all fuse holders. All fuses must be properly
installed.
7. Check all motor thermal overload settings against the
rating plate figures. Push the thermal manual reset
button on all motor starter overloads.
8. Check that all items shipped loose or unassembled such
as control panel, thermostats, etc. have been correctly installed.
9. Check that all external electrical controls and interlocks have been correctly mounted and wired.
10. Check that all power supplies and control wiring has
been inspected and approved by the Local Authorities having jurisdiction.
11. Check setpoints of temperature controls. Refer to
the wiring diagram on the duct furnace and set to
67
the temperature settings indicated. The temperature
limiting control setpoints are given below for most
duct furnace installations, however refer to the wiring diagram.
High Limit
200°F [93°C]
Fan Switch
125°F [52°C] On
90°F [32°C] Off
A duct furnace should never be allowed to cycle over
a prolonged period on the high limit. The high limit
is not an operating but a safety control to prevent
excessive temperatures. If cycling on the high limit is
noted, corrective measures should be taken immediately. Failure to do so could cause damage to the
duct furnace.
12. Check burner and induced fan wheels set screws.
Tighten if necessary.
13. Check that the exhauster (induced draft fan) or vent
discharge is free of obstructions.
14. Check that the air inlet to and the air discharge from the
duct furnace are free of obstructions.
15. Check that the gas piping has been installed in accordance with CAN1 B149 (1,2) or NFPA 54, and has
been tested for leaks and approved.
16. Check with the local gas utility that the gas supply is
open from the street gas main to the building metering station and the metering station has been completed, tested and turned on.
17. Ensure that the type of gas (natural or propane) supplied and the gas pressure to the duct furnace corresponds with the type and gas inlet pressure indicated
on the nameplate of the duct furnace.
18. Check the gas piping to ensure that the proper drip
legs, regulators, relief valves and vent lines are installed.
19. On systems where a high pressure regulator and
relief valve are installed, check that the spring in the
high pressure regulator has been screwed down to
approximately the middle of its adjustment range.
20. Purge the gas line from the meter to the duct furnace.
Start-up Instructions
1. Before proceeding, complete the Start-up Checklist.
2. Read the Sequence of Operation, while at the same time,
tracing the sequence through the electrical wiring
diagram.
3. Set the duct furnace disconnect switch ‘On’ (fan and
burner control switches are still ‘Off’ and burner thermostat is set for no heat with main and firing valves
still closed).
4. Set fan control switch ‘On’. Run the fans without
heat to check fan operation first.
5. The duct furnace is provided with an air proving interlock switch to ensure minimum airflow over the
combustion chamber prior to burner operation. Set
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
the switch to open just below the design airflow. Adjust the air throughput to be within the range specified on the duct furnace rating plate.
6. Set the burner operating switch, controls, remote panel
switches, etc. to ‘On’ or to the ‘Winter’ position (the
main and firing valves are still closed) to check operation of the induced draft (ID) fan (if so equipped)
and burner combustion air blower. The high ambient
thermostat, if provided, is located to sense the inlet
or outdoor air temperature and set to shut down
the burner if the inlet air rises above setpoint. If discharge or room thermostats are used these should be
set to provide heat. If the duct furnace is started up
in warm weather it will be necessary to temporarily
increase the setting of these controls until the burner
control circuit is energized to check operation. Use
a signal generator if necessary to vary the signal to
the modulating actuator. The induced draft fan if so
equipped and combustion air fan should start immediately.
7. Check burner and induced draft fan (if provided) motors
for correct rotation. To reverse rotation, first set the
main electrical disconnect switch to the ‘Off’ position and then interchange any two of the three wires
feeding L1, L2 or L3 at the starter.
8. Check the amperage draw of each motor on each
phase. Refer to rating plate for Full Load Amps (FLA).
9. Check voltage at duct furnace disconnect switch. If the
power is not within 10% of rated, shut the duct furnace down and consult the power company. Voltage
should be within 2% on all phase-to-phase readings
when compared to each other. A 2% voltage difference could cause as much as a 20% current imbalance.
10. On duct furnaces equipped with modulating controls
the modulating gas valve is linked with the combustion air blower air damper. On a start sequence the
actuator should be fully open for a portion of the
purge interval, then modulate to the low fire or light
off position before an ignition attempt is made.
This is to ensure four air changes in the combustion
chamber. Check the operation of the pre-purge timers, actuator and linkages. Timers and linkages are
preset at the factory. Check that the linkage retaining screws are tight.
11. Ensure that the flue is in place and providing overfire
draft or positive pressure.
12. After the pre-purge, the ignition transformer and
pilot solenoid will be energized. Observe the ignition
spark for proper location and firmness. After the trial
for ignition time, the ignition transformer and pilot
solenoid valve are de-energized and the burner control will lock out. Reset the burner control.
13. Open the main and pilot gas valve (main and pilot
firing valves must still be closed) and purge the main
68
gas line and pilot line on the duct furnace so that gas
is supplied up to the automatic gas valve(s). Do not
purge or bleed into the combustion chamber. Check
for leaks on duct furnace piping to the automatic
shut-off valves and correct.
14. On systems where high pressure regulator and relief
valves are installed, check the gas pressure downstream of the high pressure regulator and upstream
of the appliance regulator. It must not exceed 14”
w.c. [3.48 kPa] or the value on the duct furnace rating plate. Adjust the regulator as necessary.
15. Check the operation of the main automatic gas shutoff valve(s) for through-the-valve or internal seat
leakage as outlined in the valve installation and maintenance instructions provided separately.
16. If the duct furnace has high or low pressure gas
switches, press the manual reset buttons.
17. Open the pilot manual firing valve (main firing valve must
still be closed).
18. Reset the burner control.
19. The pilot should light; if not, re-check the electrical safety
circuit. Three or four trials may be needed to purge
any air from the pilot line.
20. Refer to the specific burner control in the Burner Control
Module Troubleshooting Guide for test jack locations
and flame signal reading. The Honeywell RM7897A
burner control has an expected DC voltage of between 1.25 and 5 VDC using a 20 kohm per volt
meter. The Honeywell S89F burner control should
have a flame sensor current reading of at least 0.8
µA and steady. If the flame signal reading is less,
then re-adjust the pilot flame or realign the flame
detector. If the burner control is equipped with the
optional display module the signal can be displayed.
Reset the burner control and repeat the ignition cycle
several times to ensure a fast igniting and stable pilot
flame. Contact Venmar CES Customer Service at
1-866-4-VENMAR (1-866-483-6627) or email tech
support at venmarservice@venmarces.com for a copy
of the burner control technical manual for further
information if required.
21. Open the main manual firing valve. Once the main automatic valve(s) are energized and after the low fire
timing relay has elapsed, the control valve actuator
will modulate to the setpoint temperature.
22. Check for leaks on duct furnace piping after the automatic shut-off valves and correct.
23. Check combustion air and firing rate settings. The unit
has been test fired in the factory for firing rate and
combustion. Combustion air and gas linkages have
been preset for proper combustion and high and low
fire positions have been factory preset. Field conditions, vibration, loose, damaged or replacement parts
may require adjustments to be made. These checks
should be done by a qualified service technician.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
a. Remove the signal wire to the burner modulating
actuator (Terminals G+ and G−, refer to the
electrical diagram for accurate information) and
install a 0–10 volt signal generator if this has not
been done per Item 6 in the Start-up Instructions.
Dial the signal generator to 10 volts. Check the
burner manifold pressure at the test point nearest
the burner, downstream of the gas control valve
against the nameplate for the correct pressure
and adjust the appliance regulator if necessary.
b. Check the temperature rise across the heat exchanger against the nameplate. The downstream
measurement should be done sufficiently far
downstream where the air temperature readings
are even. If the temperature rise is off from the
nameplate, then the airflow should be corrected.
Note mass flow is affected by temperature and
temperature rise should be corrected accordingly. The duct furnace should not be allowed to
operate above a maximum temperature rise of
115°F [64°C]. Temperature rise is based on 70°F
[21.1°C] or standard air conditions. This is a constant volume fan, therefore if the air temperature
to the supply fan is less than 70°F [21.1°C] the
air will be denser and the mass flow rate will increase which will result in a smaller temperature
rise according to the perfect gas law formula:
TRa = TRd * (460 + 70)/(460 + Ti)
Where:TRa = temperature rise actual (°F)
TRd = Temperature rise design (°F)
Ti = Inlet temperature at the supply fan (°F)
460 = Absolute temperature (°F)
IMPORTANT
This is an approximation as the airflow increase will cause
an increase in static pressure and hence reduce the mass
flow slightly and the motor and fan input will also provide a slight increase in temperature rise.
c. Check the overfire draft or positive pressure at maximum input against the nameplate. Make certain
that it does not exceed the maximum shown on
the nameplate. For power venting the overfire
draft should be adjusted at the damper of the
induced draft (ID) fan when the duct furnace is
operating on high fire.
d. Check the CO (Carbon Monoxide) and O2 (Oxygen)
reading at maximum input. O2 readings typically
range from 3%–16%. Calculate the AFCO (Air
Free CO) reading using the formula: AFCO =
(20.9 *COppm)/(20.9–O2%). Adjust the air/gas
ratios with the control linkages to keep the AFCO
reading below 400. Refer to Burner Linkage and
Low Fire Adjustment for the adjustment proce-
69
dure based on the type of linkage supplied with
the duct furnace.
e. Set the signal generator to a midpoint then minimum temperature rise. Repeat Step D above.
f. If the AFCO is over the acceptable limit or if there
is any burner performance problem, refer to
Burner Linkage and Low Fire Adjustment.
24. When the duct furnace installation is complete, start
and stop the burner several times to ensure proper
operation. Check the amperage draw of each motor.
25. Check operation of the burner control by simulating
a flame failure making certain the burner control
locks out within the proper time. Contact Venmar
CES Customer Service at 1-866-4-VENMAR (1-866483-6627) or email tech support at venmarservice@
venmarces.com for a copy of the burner control technical manual for further information if required.
26. Ensure all safety controls are operative (i.e. burner control, high limit, air proving switches, etc.).
27. Reset all operating controls back to proper setpoints for
normal running conditions.
28. Initial start-up has a tendency to relieve the tightness of
nuts, bolts and setscrews. Re-check for tightness of
hold down bolts, all set screws and keys, and tighten
if necessary after approximately eight hours of continuous operation.
Restarting After Ignition Failure
!
WARNING
Do not attempt to start the burner if the duct furnace is full
of vapor or gas, or if the combustion chamber is very hot.
1. Consult the burner control technical manual for
troubleshooting information. If the duct furnace is
equipped with the electronic burner control check
the status lights on the face of the control. The optional keyboard display module can also provide a
wealth of control information and fault history.
2. Set burner control switches to the ‘Off’ position.
3. Set the electrical disconnect to the ‘Off’ position.
4. Check for fuel supply.
5. Check the components in the electrical circuit to the
burner control. Check that all screws and connections are tight on the burner control.
6. Close the main manual firing valve.
7. Check the flame detector and flame ignitor. The
flame detector and ignitor are located on the combustion head assembly inside the burner and are accessible through the housing cover as shown in the
figures below.
8. Check the condition of the electrical connections and
the condition and positioning of the flame rod and
spark ignitor. On C4 burners the flame rod protrudes
in the center of the retention plate hole and the porVCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
celain should be flush with the retention plate as in
Figure D15 and Figure D16. The flame rod protrudes
in the center of the retention plate hole and extends
3-5/8” [92 mm] past on size C6 to C10 burners as in
Figure D17 and Figure D18.
9. The spark ignitor is bent at 900 at the tip. On C4
burners the ignitor tip is within 1/16” to 1/8” [1.6 to
3.2 mm] of the pilot gas deflector plate as in Figure
D15 and Figure D16. On C6 to C10 burners the perpendicular tip portion should be flush with the retention plate and within 1/16” to 1/8” [1.6 to 3.2 mm] of
the retention plate as in Figure D17 and Figure D18.
10. Follow the procedures for start-up. Should there be a demand for heat, the duct furnace should attempt to start.
11. Observe the operation very carefully to determine at
what point the trouble occurs if it still exists. Consult the burner control technical manual for further
troubleshooting procedures.
12. Burner parts for C4 burner outlined in Figure D15:
1 Combustion head
9 Burner housing
10 Air damper
11 Damper shaft
12 Back plate
14 Air inlet cone and screen
15 Motor mounting plate
16 Retention plate
20 Electric motor
21 Ignition transformer
22 Airflow switch
26 Linkage arm
27 Control quadrant
28 Site glass retainer
29 Site glass
30 Site glass gasket
31 Ignition electrode
32 Flame rod
33 Junction box
45 Blower wheel
27
12
29
30
26
30
29
30
9
10
22
33
11
6
45
47
51
14
19
46
32
50
18
1
31
15
20
48
4
49
16
21
Figure D15: C4 burner description
70
Shut Down Instructions
P/N 033
P/N 022-1
T68-7C
General
P/N 042
P/N 036
P/N 029
P/N 044
P/N 035 for 5½” nose
P/N 035-1 for 8” nose
Flame rod holder
P/N 043
1. Set the burner operating switch, controls, remote panel
switches, etc. to ‘Off’ or to the ‘Summer’ position.
2. To prevent possible gas leaks close the main manual
gas valve.
3. If the duct furnace was firing at the time of shut
down allow the supply fan blower to run for a sufficient period to cool off the heat exchanger, approximately five minutes.
4. Set the duct furnace disconnect switch to ‘Off’.
Emergency Shut Down Only
P/N 040-1 for 5½” nose
P/N 040-2 for 8” nose
0.500 NY
FW 375-125
1. Set the duct furnace disconnect switch to ‘Off’.
2. Close the main manual gas valve.
Figure D16: C4 burner combustion head assembly
12
29
30
28
Summer Shut Down
1. If the duct furnace is not required during periods
when summertime temperatures drop, then set the
burner operating switches, controls, remote panel
switches, etc. to ‘Off’. Set the duct furnace disconnect
switch to ‘Off’ and close the main manual gas valve.
2. If the duct furnace is to be used for short periods of heating, then set the operating switches, controls, remote
panel switches, etc. to the desired position(s).
33
22
30
20
45
14
15
21
17
Maintenance
32
16
11
19
10
!
1
26
9
27
2
25
23
18
31
24
5
Figure D17: C6–C10 burner description
¼”
3-5/8”
WARNING
Provincial or state regulations frequently require that
service mechanics that work on electrical equipment
must be licensed. Although many maintenance items
do not require the service of a licensed mechanic, it is
recommended that a licensed mechanic supervise any
work done on the duct furnace by unlicensed personnel.
Unqualified personnel should not be allowed to work
unsupervised.
Recommended Maintenance
IMPORTANT
1/16”–1/8”
Figure D18: C6–C10 burner combustion head
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
The following recommended maintenance schedule
should be followed every four months unless otherwise
specified below. It is highly recommended to schedule
the maintenance of the duct furnace in the spring and
fall as demands are commonly most critical after these
periods and serve as good prevention practice. Where
the duct furnace is operating under unusual amounts of
dust or if other impurities are contained in the air, more
frequent inspections are recommended.
1. Inspect the area and make certain that no combustible or hazardous material has been stored within
the clearances as shown on the nameplate.
71
2. Inspect the stack to make certain there are no obstructions. Check for carbon deposits, soot, scale or rust.
3. Inspect the condensate and drain connections and
disposal systems. Check for blockage and trap operation. Clean as applicable.
4. Ensure that there are no obstructions blocking the air
supply to the duct furnace or the air discharge from
the duct furnace.
5. Check for any vibration or unusual noise. If any are
observed, locate the cause and correct.
6. Electrical – Check all wiring for loose connections.
Check voltage at the unit (while in operation). Check
amperage draw against nameplate ratings. All contactors should be inspected to ensure that contacts
are clean and are making good contact. If contacts
are pitted or burned badly, replace contactor points.
Single phasing and motor burn out may result from
bad contacts. Check all fuses and replace blown
fuses with equivalent size and type.
7. Controls – Clean and recalibrate all controls and
check for proper operation. Repair or replace any
controls found faulty.
8. Gas Piping – Check all fittings, valves and lines for leaks.
Ensure all vents to atmosphere are clean and free
from obstruction. Inspect and clean all drip legs
in the fuel line. Inspect all regulators, relief valves,
vent valves, manual shut-off valves and gas pressure
switches. Check their operation and clean or replace
as necessary. Check the operation of the main automatic gas shut-off valve(s) for through-the-valve or
internal seal leakage as outlined in the valve installation and maintenance instructions provided separately. Check the fuel supply pressure to the duct
furnace.
9. Motors – Inspect motors every three months or 500 hours
of operation, whichever is less. Keep the motor clean
and the ventilation openings clear. Make certain the
mechanical installation is secure and all bolts and
nuts are tightened. Check all electrical connectors
to be certain that they are tight. Use a Megger periodically to ensure that the integrity of the winding
insulation has been maintained. Record the readings
and investigate any significant drop in insulation resistance.
10. Motor Lubrication – Some motors are complete
with permanently lubricated and sealed bearings,
which do not require lubrication. Motors with grease
nipples and drain plugs have been filled by the Manufacturer and should always be checked before startup and at regular intervals.
a. A recommended lubrication schedule for motors
is given in Table D3 for normal operation. Where
conditions are more severe or abnormal the re-lubrication interval should be reduced. Refer to the
motor Manufacturer’s instructions. Motors that
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
run in hot, severe dirt or wet conditions should be
lubricated at least every six months.
Table D5: Re-lubrication Schedule
Hours of
Service
(hours/day)
Less than 12
Up to 7.5 HP
10–40 HP
Over 40 HP
5 years
3 years
1.5 years
More than 12
2 years
1 year
9 months
Re-lubrication Interval
b. Be sure the grease that is being added to the
motor is compatible with the grease already in the
motor. Consult the motor Manufacturer if grease
other than Mobil or Polyrex EM is to be used.
c. Clean the grease nipple. Remove the outlet plug.
With motor stopped, add grease slowly until new
grease appears at the shaft hole in the end plate
or purge outlet plug. Re-install outlet plug.
11. Burner – Inspect the burner and combustion air
blower, clean if necessary. See Figure D15 to Figure
D18. To clean the combustion air blower, disconnect
the wiring on the burner motor, remove the blower/
motor assembly and vacuum the blades or blast with
compressed air to remove any dirt buildup. Inspect
the flame sensor and ignition electrode and check for
cracks, positioning and gap. Test the ignition spark
and flame signal. Check that the modulating actuator
linkages are tight and operate freely. Perform the final
combustion check per Start-up Instructions, Item 24.
Recommended Spare Parts – General
1. Spare parts should be ordered at the time the installation
if accepted by the Owner. Spare parts will reduce the
down time in the event of a failure.
2. The list of spare parts outlined below is considered
minimum. Installations in remote locations or where
duct furnace operation is essential may require more
spare parts than listed. Please contact our service department for recommendations.
3. Minimal spare parts list:
• Two sets of fuses
• One burner control relay module, flame signal
amplifier and purge card
• One flame sensor
• One spark igniter
72
Burner Linkage and Low Fire Adjustment
!
WARNING
Do not attempt to start the burner if the duct furnace is
full of vapor or gas, or the combustion chamber is very hot.
5.
General
1. The procedure in this section needs to be performed
only if the performance of the burner is not satisfactory. Refer to Start-up Instructions for directions on
how to determine if this procedure is needed.
2. Refer to the notes in the Introduction, at the beginning, and the Duct Furnace Start-up and Operation
sections before continuing.
3. Determine the type of linkage employed on the duct
furnace and proceed to the corresponding section
below.
6.
7.
Cam Linkage
1. A cam linkage is used on positive fired combustion chambers up to and including 1,400 mbh with
natural gas and for 7” w.c. inlet pressures only to
provide optimum air and gas ratios for combustion
throughout its firing range and provides maximum
turndown of the burner. The combustion air damper
control arm is fitted with a roller bearing and follows
a characterized cam as shown in Figure D19. The gas
butterfly valve is fitted with adjustable control arms
and fixed linkages to the actuator.
8.
Figure D19: Cam linkage
2. For your safety and to avoid damaging the equipment, start the linkage and low fire adjustment procedure without gas or power to the duct furnace.
3. Make certain all the joints on the control arms and linkages are tight to begin with. Loose joints could make
the adjustment slip and create an unsafe condition.
4. Remove the signal wire to the burner modulating actuator (Terminals G+ and G−, refer to the electrical diagram for accurate information) and install a 0–10 volt
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
9.
signal generator if this has not been done per Item
6, Start-up Instructions. Dial the signal generator to
2 volts or less. With power off the actuator and linkage should position the combustion air damper to an
opened position for maximum air throughput.
Close the manual firing valve (M4, refer to the piping diagram), power up the unit and open the main
manual gas shut-off valve (M1) to the unit.
Start the burner and wait for the purge to complete.
During the purge, the combustion air damper should
move from maximum purge position (opened position for maximum air throughput) to low fire (closed
position for light off). At the same time, the gas butterfly valve should rotate from high fire (open position for maximum gas throughput) to low fire (closed
position for light off).
After the purge, the pilot will ignite. Once the pilot is
lit, slowly open the manual firing valve (M4); at the
same time look into the burner view port and watch
for any flame rolling back around the burner profile
plate. If this happens, the amount of gas should be
reduced at the butterfly valve before continuing.
Loosen the swivel joint on the connecting rod at the
butterfly crank arm and slide the rod to close the
valve very slightly. Flame rolling back into the burner
could damage some internal burner components. A
yellow flame is normal on low fire.
Once you have successfully established low fire, start
to modulate the burner slowly to high fire, taking a
close look at the flame to make sure it runs smoothly
and does not roll back into the burner. Once the full
modulation (10 volts to the actuator) is reached, verify the gas supply pressure to the unit to make sure
it is at least equal to the minimum rated pressure on
the nameplate. Please note that the cam follower is
not necessarily going to reach the high fire end of
the cam profile as the cam can be adjusted for a partial input.
Verify the manifold and overfire pressures (chamber
pressure). The differential between the manifold and
the overfire should be the same as what can be calculated from the values indicated on the nameplate.
If it is not correct, increase or decrease the manifold
by adjusting the appliance pressure regulator (M3 or
SV1). Verify the temperature rise as per the instructions under Start-up Instructions, Item 23b.
Return to the low fire position (less than 2 volts modulation signal). Verify the position of the air damper
in the burner. The cam follower, mounted on the gas
butterfly valve, should be at one end of cam profile.
See Figure D20.
Adjust the gas butterfly valve opening to obtain a clean
combustion on the low fire position. Make sure the
Air Free CO (AFCO) is maintained below 400 ppm.
73
Figure D20: Low fire typical cam positioning
10. Verify the combustion to make sure it is clean in the
intermediate range and on high fire.
11. When the duct furnace adjustment procedure is
complete, start and stop the burner several times to
insure proper operation.
Fixed Linkage
1. A fixed linkage is used where cam linkage conditions
are not met to provide proper air and gas ratios for
combustion throughout its firing range and provides
limited turndown of the burner. Both the combustion
air damper and the gas butterfly valve are fitted with
adjustable control arms and fixed linkages to the actuator.
2. For your safety and to avoid damaging the equipment, start the linkage and low fire adjustment procedure without gas or power to the duct furnace.
3. Make certain all the joints on the control arms and linkages are tight to begin with. Loose joints could make
the adjustment slip and create an unsafe condition.
4. Remove the signal wire to the burner modulating actuator (Terminals G+ and G−, refer to the electrical diagram for accurate information) and install a 0–10 volt
signal generator if this has not been done per Startup Instructions, Item 6. Dial the signal generator to 2
volts or less. With power off, the actuator and linkage should position the combustion air damper to an
opened position for maximum air throughput.
5. Close the manual firing valve (M4, refer to the piping diagram), power up the unit and open the main
manual gas shut-off valve (M1) to the unit.
6. Start the burner and wait for the purge to complete.
During the purge, the combustion air linkage should
move from maximum purge position (opened position for maximum air throughput) to low fire (closed
position for light off).
7. After the purge, the pilot will ignite. Once the pilot is lit,
slowly open the manual firing valve (M4). Look into
the burner view port at the same time and watch
for any flame rolling back around the burner profile
plate. If this happens, the amount of gas should be
reduced at the butterfly valve before continuing.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Loosen the swivel joint on the connecting rod at the
butterfly crank arm and slide the rod to close the
valve very slightly. Flame rolling back into the burner
could damage some internal burner components. A
yellow flame is normal on low fire.
8. Once you have successfully established low fire, start to
modulate the burner slowly to high fire, taking a
close look at the flame to make sure it runs smoothly
and does not roll back into the burner. Verify that
the notch on the end of the shaft of the gas butterfly
valve (M5) does not go past the maximum opening
(notch parallel to the gas line). If it does, reduce the
span on the burner actuator. Once the full modulation (10 volts to the actuator) is reached, verify the
gas supply pressure to the unit to make sure it is at
least equal to the minimum rated pressure on the
nameplate.
9. Verify the manifold and overfire pressures (chamber pressure). The differential between the manifold and the
overfire should be the same as what can be calculated from the values indicated on the nameplate.
If it is not correct, increase or decrease the manifold
by adjusting the appliance pressure regulator (M3 or
SV1). The burner air damper opening should also be
adjusted to get a clean combustion. When it is done,
indicate the high fire air damper position on the slotted quadrant attached to the burner air damper rod.
Verify the temperature rise as per the instructions
under Start-up Instructions, Item 23b.
10. Return to the low fire position (less than 2 volts modulation signal). Verify the position of the air damper in
the burner. It should be at the mark indicated on the
slotted quadrant from factory adjustments.
11. Adjust the butterfly valve opening to obtain a clean combustion on low fire position. Make sure the Air Free
CO (AFCO) is maintained below 400 ppm. If you cannot obtain a clean combustion on low fire, you might
have to change the burner air damper opening. Put a
reference mark of the low fire air damper position on
the slotted quadrant.
12. Shut the burner and the entire unit off and turn the
power to the unit off. If you do not turn the power
off, the burner actuator will continue to modulate
and will make the adjustments harder to perform.
13. Use the manual override push button on the burner
modulating actuator and make sure the linkage is
on the low fire position. Verify that the mark on the
quadrant still matches. Rotate the linkage to the high
fire position (the notch on the butterfly valve should
be parallel to the gas train). Verify the position
reached on the air damper quadrant versus the mark
on the quadrant.
14. If the position was not as expected on high fire, some adjustment will have to be made. Follow these steps:
a. Make sure the linkage is on the low fire position.
74
b. Tighten the burner air damper quadrant at the
screw in the slot so the linkage cannot move.
c. Loosen the rod at one of the two ball joints on
the air linkage.
d. You will now have to perform the adjustment itself. Choose the proper adjustment, depending if
the damper was not opening enough or too much:
Damper does not open enough
Move the ball joint installed on the driver shaft
further from the shaft.
Move the ball joint installed on the driven shaft
closer to the shaft.
Damper opening too much
Move the ball joint installed on the driver shaft
closer to the shaft.
Move the ball joint installed on the driven shaft
further from the shaft.
e. Tighten the rod at the ball joint and loosen the air
damper.
f. Use the manual override push button on the
actuator to verify if the linkage is now correct. If
not, go through the steps above until you get a
satisfactory setup.
15. Bring back the power to the unit and turn it on. Verify the combustion to make sure it is clean on low,
mid and high fire. Fine tune as necessary.
16. When the duct furnace adjustment procedure is
complete, start and stop the burner several times to
insure proper operation.
Run/test switch
Captive
mounting screw
Plugin
purge card
Dust cover
Sequence
status LEDs
Relay module
Reset push
button
Flame
simulator input
Flame amplifier
Flame current
test jacks
Figure D21: Flame signal measurement location
Burner Control Module Troubleshooting
Guide
RM7897A Burner Control Module
Troubleshooting
The power LED provides fault identification when the relay
module locks out on an alarm. Fault identification is a
series of fast and slow-blinking LED lights. The fast blinks
identify the tens portion of the fault code (three fast blinks
is 30), while the slow blinks identify the units portion of
the fault code (two slow blinks is two). Three fast blinks
followed by two slow blinks would be fault code 32. This
identifies a running interlock on during standby (see Table
D4 for Blinking Fault Code List.)
The LED code repeats as long as the fault exists. To clear
the fault, press the Reset button.
IMPORTANT
Blink codes do not match fault codes viewed by an
S7800 KDM.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
75
Table D6: Blinking Fault Codes and Recommended Troubleshooting
Fault Code
System Failure
Code 1-1: Low AC
Low AC line detected.
line voltage
Code 1-2: AC
quality problem
Excessive noise or device running on slow,
fast or AC line dropout detected.
Code 2-1:
Unexpected flame
signal
Flame sensed when no flame is expected during standby or purge.
Code 2-2: Flame
signal absent
No flame time present at the end of the pilot
flame establishing period; lost during the
main flame establishing period or during run.
Code 2-3: Flame
signal over range
Flame signal value is too high to be valid.
Code 3-1:
Running/interlock
switch problem
Running or lockout interlock fault during prepurge.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Recommended Troubleshooting
1. Check the relay module and display module connections.
2. Reset and sequence the relay module.
3. Check the 7,800 power supply and make sure that frequency and
voltage meet specifications.
4. Check the backup power supply, as appropriate.
1. Check that flame is not present in the combustion chamber, correct any errors.
2. Make sure that the flame amplifier and flame detector are compatible.
3. Check the wiring and correct any errors.
4. Remove the flame amplifier and inspect its connections. Reset the
amplifier.
5. Reset and sequence the relay module.
6. If the code reappears, replace the flame amplifier and/or the flame
detector.
7. If the fault persists, replace the relay module.
1. Measure the flame signal. If one exists, verify that it meets
specifications.
2. Make sure that the flame amplifier and flame detector are compatible.
3. Inspect the main fuel valve(s) and valve connection(s).
4. Verify that the fuel pressure is sufficient to supply fuel to the
combustion chamber. Inspect the connections to the fuel pressure
switches. Make sure they are functioning properly.
5. Inspect the airflow switch and make sure that it is functioning
properly.
6. Check the flame detector sighting position; reset and recycle. Measure the flame signal strength. Verify that it meets specifications.
If not, refer to the flame detector and/or flame amplifier checkout
procedures in the installation instructions.
7. Replace the flame amplifier and/or the flame detector, if necessary.
8. If the fault persists, replace the relay module.
1. Make sure the flame detector and flame amplifier are compatible.
2. Remove the flame amplifier and inspect its connections. Reset the
flame amplifier.
3. Reset and sequence the relay module.
4. Check the flame detector sighting position; reset and recycle. Measure flame strength. Verify that it meets specifications. If not, refer
to the flame detector and/or flame amplifier checkout procedures
in the installation instructions.
5. If the code reappears, replace the flame amplifier and/or the flame
detector.
6. If the fault persists, replace the relay module.
1. Check wiring; correct any errors.
2. Inspect the fan; make sure there is no air intake blockage and that
it is supplying air.
3. Make sure the lockout interlock switches are functioning properly
and the contacts are free from contaminants.
4. Reset and sequence the relay module to pre-purge (place the test/
run switch in the ‘Test’ position, if available). Measure the voltage
between Terminal 7 and G (Ground); 120 VAC should be present.
Switch test/run back to ‘Run’.
5. If Steps 1 through 4 are correct and the fault persists, replace the
relay module.
76
Table D6: Blinking Fault Codes and Recommended Troubleshooting
Fault Code
System Failure
Recommended Troubleshooting
1. Check wiring to make sure that the lockout interlocks are connected properly between Terminals 6 and 7. Correct any errors.
2. Reset and sequence the relay module.
3. If the fault persists, measure the voltage between Terminal 6 and
G (Ground), then between Terminal 7 and G. If there is 120 VAC
at Terminal 6 when the controller is off, the controller switch may
Code 3-2:
Lockout interlock powered at improper point
be bad or is jumpered.
Running/interlock
in sequence or on in standby.
on during standby
4. If Steps 1 through 3 are correct and there is 120 VAC at Terminal
7 when the controller is closed and the fault persists, check for a
welded or jumpered running interlock or airflow switch. Correct
any errors.
5. If Steps 1 through 4 are correct and the fault persists, replace the
relay module.
1. Check wiring, making sure upstream valve is connected to Terminal 9 and downstream valve is connected to Terminal 17.
2. Conduct valve seat leakage test using a manometer.
Code 3-3: VPS in
VPS (valve proving switch) in wrong state
3. Reset and sequence the relay module; if fault repeats, test VPS (conimproper state
during VPS test.
nected to Terminal 16) is functioning properly; replace if necessary.
4. Reset and sequence the relay module.
5. If fault persists, replace the relay module.
1. Make sure the purge card is seated properly.
2. Inspect the purge card and the connector on the relay module for
any damage or contaminants.
Code 4-1: Purge
No purge card or the purge card timing has
3. Reset and sequence the relay module.
card problem
changed from the original configuration.
4. If the fault code reappears, replace the purge card.
5. Reset and sequence the relay module.
6. If the fault code persists, replace the relay module.
! WARNING
Code 4-2: Wiring
problem/internal
fault
Code 4-3: Flame
amplifier problem
Code 4-4:
Configuration
jumper problem
Electrical shock hazard/fire or explosion hazard – Can cause severe
injury, death or property damage. Remove system power and turn off
power supply.
Pilot (ignition) valve terminal, main valve, ignition or main valve 2 was on when it should 1.
be off.
2.
3.
4.
5.
1.
2.
3.
Flame not sensed or sensed when it should
be on or off.
4.
5.
6.
1.
The configuration jumpers differ from the
sample taken at start-up.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
2.
3.
Remove system power and turn off fuel supply.
Check wiring; correct any errors.
Inspect pilot fuel valve(s) (both places) and connections.
Reset and sequence the relay module.
If the fault persists, replace the relay module.
Check wiring; correct any errors.
Make sure the flame amplifier and flame detector are compatible.
Remove the flame amplifier and inspect the connections. Reset the
amplifier.
Reset and sequence the relay module.
If the code reappears, replace the flame amplifier and/or the flame
detector.
If the fault persists, replace the relay module.
Inspect the jumper connections. Make sure the clipped jumpers
were completely removed.
Reset and sequence the relay module.
If the fault persists, replace the relay module.
77
Table D6: Blinking Fault Codes and Recommended Troubleshooting
Fault Code
System Failure
Recommended Troubleshooting
1. Inspect the jumper connections. Make sure the clipped jumpers
were completely removed.
Pre-ignition interlock fault.
2. Reset and sequence the relay module.
3. If the fault persists, replace the relay module.
1. Check wiring and correct any errors.
2. Reset and sequence the relay module.
3. Use manual motor potentiometer to drive the motor open and
Code 5-2: High fire
closed. Verify at motor switch that the end switches are operating
switch or low fire Either high fire switch or low fire switch failure.
switch
properly. Use run/test switch if manual potentiometer is not available.
4. Reset and sequence the relay module.
5. If the fault persists, replace the relay module.
1. Check wiring and correct any errors.
2. Make sure that the manual open valve switch, start switch and
control are operating properly.
Code 5-3: Manopen switch, start Man-open switch, start switch or control on 3. Stat switch held ‘On’ too long.
switch or control
in the wrong operational state.
4. Reset and sequence the relay module.
on
5. Reset and sequence the relay module. If the fault persists, replace the relay module (RM7838A1014; RM7838B1013 or
RM7838C1004 only).
1. Reset and sequence the relay module.
2. If fault re-appears, remove power from the device, re-apply power,
Code 6-1: Internal
Relay module self-test failure.
faults
then reset and sequence the relay module.
3. If the fault persists, replace the relay module.
1. Reset and sequence the relay module.
2. If fault re-appears, remove power from the device, re-apply power,
then reset and sequence the relay module.
Code 6-2: Internal
Relay module self-test failure.
3. If fault does not repeat on the next cycle, check for electrical noise
faults
being copied into the relay module through the external loads or
possibly an electrical grounding issue.
4. If the fault persists, replace the relay module.
1. Check wiring and operation of special OEM inputs.
2. Reset and sequence the relay module.
3. If fault re-appears, remove power from the device, re-apply power,
then reset and sequence the relay module.
Code 6-3: Device
Fault with special OEM input circuits.
specific
4. If the fault does not repeat on the next cycle, check for electrical
noise being copied into the relay module through the external
loads or possibly an electrical grounding issue.
5. If the fault persists, replace the relay module.
Code 6-4:
Unused at this time.
—
Accessory fault
Cod 7-7: Unused
Unused at this time.
—
Code 5-1:
Pre-ignition
interlock
S89 Burner Control Module
Measure Flame Current
The S89 provides AC power to the flame sensor which the
flame rectifies to direct current. If the flame signal back
to the S89 is less than 0.8 µA, the S89 will shut down the
system.
To measure the flame current:
1. Connect a meter, set to the dc microammeter scale,
in series with the flame sensor as shown in Figure
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
D22. Use the Honeywell W136 Test Meter or equivalent. Connect the meter as follows:
a. Disconnect the sensor lead at the S89.
b. Connect the red (positive) meter lead to the S89
sense terminal.
c. Connect the black (negative) meter lead to the
free end of the sensor lead.
2. Restart the system and read the meter. The flame
sensor current must be at least 0.8 µA and steady.
78
3. If the meter reads less than 0.8 µA or reading is unsteady, recheck points under Check Flame Sensor
and Igniter.
Flame sensor current check – use µA scale
To sensor
W136 (or equivalent)
multi-purpose meter
Valve
Valve (Gnd)
Disconnect
wire from
sense terminal
24V
24V (Gnd)
Sense
Gnd (burner)
Black (−)
Red (+)
0.8 µA DC min.
(and steady)
Figure D22: S89 flame current measurement
Check burner flame condition
Noisy lifting flame
Check for:
• High gas pressure
• Excess primary air
or draft
Burner
Waving flame
Check for:
• Poor draft
• Excess draft
• High velocity or
secondary air
Install shield if necessary
Small blue flame
Check for:
• Clogged ports or
orifice filter
• Wrong size orifice
Lazy yellow flame
Operation
The S89 is powered by a 24V transformer. It operates in
response to a call for heat from the thermostat.
On every call for heat, the S89 performs a safe start check.
If a flame or a flame simulating condition is present, the
S89 locks out without starting the igniter and must be reset.
Following the safe start check and, on the S89F, a valve
on delay period, the S89 spark generator contacts close to
energize the spark generator and the igniter. At the same
time the gas control, powered through the gas valve relay
contacts in the S89, opens so gas can flow to the burner.
The igniter is on during approximately the first 80 percent
of the ignition, or lockout timing, period. During the balance of the lockout timing period, the ignition is off and
the flame sensor attempts to prove the flame. The flame
is proved when current from the flame sensor through the
burner flame to ground reaches 0.8 µA dc.
If flame is proved, the gas control remains open and the
burner on until the call for heat ends.
If flame is not proved, the gas control closes and the system is locked out until the S89 is reset.
If flame is lost after being proved, the S89 will close the
gas control, perform a safe start check, and, on the S89F,
valve on delay, then return ignition as described above.
The S89 is reset by turning the thermostat below room temperature or removing power to the system for 45 seconds.
Start
1. Thermostat calls for
heat.
Safe start
check
2. Safe start check.
Valve on delay
(S89F only)
Trial for
ignition
Check for lack
of air from:
• Dirty primary
air opening
• Large ports
or orifices
Good rectifying flame
1” [25.4 mm]
¼–½” [6.4–12.7 mm]
Figure D23: Check burner flame condition
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Burner
operation
End
2A. Valve on delay
(S89F only)
combustion air
blower starts.
Power interruption.
System shuts off.
Restarts when power
is restored.
If flame simulation
condition is present,
system will not start.
3. Spark generator
powered. Ignition
begins and gas
control opens.
If no spark, S89 locks
out and shuts down
system. Must be
reset.
4. Burner lights.
Ignition stops and
flame current is
sensed.
If flame current is
absent, weak or
unsteady, S89 locks
out and shuts down
system. Must be
reset.
5. Burner runs, S89
monitors flame
current.
If flame is lost, S89
closes gas control,
then restarts safe
start check and trial
for ignition.
6. Thermostat satisfied.
Gas control closes,
burner goes off.
Figure D24: Normal sequence of operation
79
Troubleshooting
!
Check Spark Ignition Circuit
WARNING
Fire or explosion hazard. Can cause severe injury, death,
or property damage.
Any replacement S89 must have the same or shorter lockout timing and the same or longer delay timing as the
original control.
IMPORTANT
1. The following service procedures are provided as a
general guide. Follow Appliance Manufacturer service instructions, if available.
2. All meter readings must be taken within the trial
for ignition period. Once the ignition period ends,
the system must be reset by setting the thermostat
down for at least 45 seconds before continuing.
3. If any component does not function properly, make
sure it is correctly installed and wired before replacing it.
4. The ignition module cannot be repaired. If it malfunctions, it must be replaced.
5. Only trained, experienced service technicians should
service direct spark ignition systems.
Before beginning troubleshooting, review the normal operating sequence of the S89. See the Operation section.
Then follow the steps in Fig. 5 to identify the source of the
problem. Some steps are explained in greater detail below.
Besides standard hand tools, you will need the following
to complete the troubleshooting:
1. Honeywell W136 Test Meter or equivalent.
2. Test lead – A length of ignition cable or other heavily
insulated wire with both ends stripped ½” [13 mm].
Check Ignition System Grounding
Nuisance shut downs are often caused by a poor or erratic
ground.
A common ground is required for the module, igniter,
flame sensor and main burner.
1. Check for good metal-to-metal contact between the
igniter bracket and the main burner.
2. Check the ground lead from the GND (burner) terminal on the module to the igniter bracket. Make sure
connections are clean and tight. If the wire is damaged or deteriorated, replace it with 14 to 18 gauge,
moisture resistant, thermoplastic insulated wire with
a 221°F [105°C] minimum rating. Use a shield if necessary to protect the ground wire from radiant heat.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
The S89 spark generator relay switches 120 VAC to the
remote mounted spark generator, which, in turn, powers
the spark igniter at the burner. Check as follows:
1. Shut off gas supply to the gas control.
2. Disconnect the ignition cable at the spark generator
stud terminal.
3. Set the thermostat to call for heat.
4. Reset the S89 by removing power to the module for
45 seconds.
!
WARNING
Electrical shock hazard. Can cause severe injury, death, or
property damage.
In the next step, do not touch either the stripped end of
the test lead or the stud terminal.
5. Restore power. Before the S89 locks out, touch one
end of the test lead firmly to the S89 GND terminal.
Do not remove the existing ground lead.
6. Slowly move the other end of the test lead toward
the stud terminal on the spark generator until sparking stops.
7. Slowly pull the wire away from the stud terminal and
note the size of the gap when sparking stops.
8. Follow instructions in Table D7.
Table D7: Spark Ignition Troubleshooting
If the gap was
Then
1/8” [3 mm] or more
Generator output voltage is okay.
Check for 120 VAC at the spark generator terminals. If okay, replace the
spark generator.
Less than 1/8” [3 mm] or
no spark
Check Flame Sensor and Igniter
1. Make sure burner flame is capable of providing a
good rectification signal. See Figure D23.
2. Make sure about ¾” to 1” [19 to 25 mm] of the
flame sensor is continuously immersed in the flame
for best flame signal. See Figure D23. Bend the
bracket or flame sensor, or relocate the sensor as
necessary. Do not relocate the igniter.
3. Make sure flame does not touch sensor or ignitor
ceramic insulator and that insulators are below he
flame. Excessive heat (over 1,000°F [538°C]) will
cause short to ground. Move sensor to cooler location or shield insulators if excessive heat is suspected.
Do not relocate the igniter.
4. Check for cracked igniter or sensor ceramic insulator,
which can cause short to ground, and replace unit if
necessary.
5. Make sure electrical connections are clean and tight.
6. Replace damaged wire with moisture resistant number
18 wire rated for continuous duty up to 221°F [105°C].
80
Start
Review normal operating
sequence. Turn gas supply
on. Turn thermostat up to
call for heat.
Power to S89 (24 VAC and
120 VAC Normal).
No
Check line voltage power. Low voltage transformer, limit controller, thermostat
and wiring. Also, air proving switch on pre-purge systems (see wiring hookups).
Yes
S89E – 10 second max.
Delay for safe start check.
No
Replace S89.
S89F only – 38 second max.
Valve-on delay.
Yes
Spark across igniter gap.
No
Check spark ignition circuit.
No
See component checks.
Spark ok?
•
•
•
Check for 120V to spark generator.
Replace spark generator if voltage ok.
If no voltage, replace S89.
Yes
Make sure ignition cable:
• Provides electrical continuity.
• Does not touch any metal surfaces.
• Connections are metal surfaces.
• Shows no signs of melting or buckling. Replace and shield cable if necessary.
Yes
Make sure burner spark igniter and S89 ground (burner) terminal have
effective common ground. Poor or erratic ground will cause nuisance shutdowns.
Check for cracked insulator on igniter or flame sensor. Replace device with
cracked insulator to prevent short to ground.
Main burner lights.
No
Note: If S89 locks out, reset before continuing.
•
•
Yes
•
Spark stops before end of
igniter timing.
No
Check for 24 VAC across valve and valve (ground) terminals on S89. If no
voltage, replace S89.
Make sure igniter and sensor are properly positioned. See component
checks.
Check electrical connections between S89 and gas control. If ok, replace
gas control.
Replace S89.
Yes
System runs until call for
heat ends.
No
Note: If S89 locks out, reset before continuing.
•
•
•
Yes
•
Call for heat ends; system
shuts off.
No
Yes
•
•
Make sure flame current is at least 0.8 micro amps. See component checks.
Make sure L1 and L2 are connected to the proper terminals.
Make sure flame does not touch sensor insulator and that sensor insulator is
below flame. Excessive heat (over 1,000ºF [538ºC] will cause short to
ground. Relocate sensor or shield insulator if excess heat is suspected.
If checks are ok, replace S89 module.
Check for proper temperature controller operation.
Remove valve lead at S89; if valve closes, recheck temperature
controller and wiring. If not, replace gas control.
Repeat procedure until trouble free operation is obtained.
Troubleshooting ends.
Figure D25: Troubleshooting S89E,F
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
81
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VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
82
Appendix E: EnergyPack®, ERV5000–10000(i/e) and
HRV3000–10000(i/e) Start-up Form and Checklist
•
•
•
•
•
•
•
IMPORTANT
Complete all forms under this appendix for each
unit and email, fax or mail to Venmar CES immediately after start-up to validate warranty and to
provide valuable information for personnel performing future maintenance or for factory assistance to
address below.
Read the Installation, Operation and Maintenance
Instruction Manual and the Venmar CES Control
System Keypad Operation Guide and the Sequence
of Operation before proceeding.
Leave a copy of this report with the owner and at
the unit for future reference and permanent record.
To ensure proper operation of each unit, qualified
personnel should perform the start-up, complete
the checklist and report.
All units are functionally tested except when
shipped in multiple pieces. Start-up adjustments
may be required. If the unit is shipped as a single
piece, blowers, enthalpy wheel and compressors (if
equipped) are set up to run correctly when power
is connected. If any blower is running backwards
or compressor is making loud noises, disconnect
power and switch two leads (on three-phase power)
to ensure proper rotation and avoid damage.
If units are equipped with compressors, power must
be turned on for 24 hours prior to a call for cooling, for the compressor crank case heaters to be
energizing to prevent possible damage.
The Bacview keypad located at the control panel
will allow for manual override for start-up, mode
of operation selection and includes an internal time
clock if remote interlocks are not provided.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Venmar CES Inc.
200 Rue Carter
St. Léonard d’Aston, QC
Canada J0C 1M0
Email to tech support: venmarservice@venmarces.com
Fax: 899-319-2612
Phone: 1-866-4-VENMAR
Unit Identification Information
Project_____________________________________________
Job Name__________________________________________
Job Address
__________________________________________________
__________________________________________________
__________________________________________________
Model Number______________________________________
Serial Number_______________________________________
Tag_ ______________________________________________
Jobsite Contact_ ____________________________________
Email______________________________________________
Telephone__________________________________________
83
Serial Number:______________________________________
Table E1: Pre Start-up Checklist
Checklist Item
1
Check the electrical disconnect set to the ‘Off’ position.
2
Check the split section joints are properly installed on multi-sectional units.
Check that all holes that have been made by the Installing Contractor after receiving the unit in the
casing, partitions or floor have been well sealed to prevent air and/or water infiltration.
Check the unit for obstructive packaging, objects near or in fans, dampers, energy recovery wheel, etc.
3
4
Check √
N/A
a. Check that the inside of unit has been cleaned of all debris.
Remove all retaining bolts on fan isolation bases.
a. Check that the fan impellers are rotating freely.
5
b. Check fan impellers and drive set screws. Tighten if required.
c. Check the fan bearing set screws or locking collars. Tight if required.
d. Check fan belt alignment and tension.
6
7
8
9
10
e. Check the fan flexible joint connections are well attached.
Check that the air filters are installed and clean. Replace if necessary. See Appendix F for optional
downstream high efficiency HEPA filter installation (if supplied).
a. Check all face mounted filters are attached with four clips each.
b. Check each sliding filter has a retainer at the end track and well attached blank-offs.
c. Check the filter pressure differential gauges, switches or sensors are free of dirt and set at a
value satisfactory to the end user to trigger a filter change.
Check coils if fins have been damaged in shipping, installation or building construction and are
clean. Straighten fins with a fin comb and clean coil if required.
a. Check all pipe connections are tight and that no damage has occurred during shipping or installation.
b. Check that the piping to the coils and WSHP have been completed, piping lines have been
flushed, filled, vented and tested at 1.2 times the operating pressure. Refer to Appendix B.
Scroll compressor RIS vibration isolator bolts are factory tightened to the correct torque setting for
operation and do not require field adjustment.
a. Check the refrigerant components and piping are in good condition and have no damage or
leaks from shipping or installation.
b. Check that the refrigerant lines are spaced at least 1” apart and from the compressor after shipping and installation.
c. Check that the refrigerant line clamps are still secure and have their rubber lining.
d. Check that the clearance around the air cooled condenser is within minimum clearance and the
discharge is not blocked.
Check motorized damper control arms, control rods and shafts for tightness.
a. Check that non motorized dampers rotate freely.
Check the energy recovery wheel media for any defects from shipping or installation. See Maintenance section for details.
a. Grease both pillow block bearings on the wheel(s) when grease nipples provided.
b. Check that the wheel(s) are turning freely by hand and do not bind.
c. Visually inspect the wheel(s) to ensure it is centered and does not tilt. If there is any indication of
a problem call Venmar CES Tech Support at 1-866-4-VENMAR.
d. Check that the wheel seals are properly positioned from the face of the wheel.
e. Check that the wheel purge (if present) is set to the default angle as specified in the submittal.
f. Check the mounting fasteners on the wheel(s) motor and gear reducer are tight.
g. Check the belt and pulley on the wheel drive for correct alignment, tension and set screw tightness.
11
Check the plate media for any defects from shipping or installation.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
84
Serial Number:______________________________________
Table E1: Pre Start-up Checklist
Checklist Item
Check √
N/A
Check √
N/A
Check the heat pipe fins for any fin defects from shipping or installation.
12
a. Remove retaining bolts on heat pipe tilt mechanism.
b. Check the heat pipe flexible connection is properly attached and sealed on tilt mechanism.
c. Check the actuator control arm and linkages are tight on tilt mechanism.
13
Check that ductwork is connected, complete and free of obstructions.
14
Check that condensate drain connections have been trapped, installed correctly and filled.
Check at all unit split sections that all factory internal high and low voltage wiring connections have
been properly re-connected.
Check that all shipped loose or field supplied components have been correctly installed and wired.
15
16
17
18
19
20
21
22
23
24
25
26
Check that the wiring diagram has been marked up accordingly and left with the unit.
Check that all power supplies and control wiring have been inspected and approved by the Local
Authorities having jurisdiction.
Check all factory and field wiring connections for tightness. Tighten if necessary.
Check that all fuses are properly installed in holders.
Check the voltage at the disconnect switch against the nameplate and against phase-to-phase
readings on three-phase. If the voltage is not within 10% of rated or 2% of phase to phase, have
the condition corrected before continuing start-up.
Check that all field piping and venting installation and connections for heating and cooling options
have been completed and tested.
Set the heating and cooling enable switches to the ‘Off’ position.
Refer to Appendix D for gas-fired furnace module and Appendix G for electric coil installation and
maintenance and check that the installation is completed. Perform all gas-fired furnace and electric
coil pre start-up checks.
Check that all safety switches, overloads or other manual reset devices are reset.
If the unit is equipped with compressors, power must be turned on with the unit in ‘Off’ mode for
24 hours before start-up. This will energize crank case heaters and assure no liquid refrigerant is
present which could cause compressor damage or failure. Check that this has been completed.
Table E2: Start-up Checklist
Checklist Item
1
Before proceeding, complete the pre start-up checklist.
2
5
Check that all access panels or doors are closed.
If units are equipped with compressors, feel the compressor crank cases. They should be warm
if the disconnect has been ‘On’ for at least 24 hours. This will assure that no refrigerant liquid is
present in the crank case which could cause compressor damage or failure to occur on start-up.
Otherwise, turn the main disconnect to the ‘On’ position.
The unit can be started by using the keypad and selecting the mode of operation from the Keypad
Operation Guide and the Sequence of Operation. Disable the heating and cooling functions and
set the unit to the occupied mode to bump start the fan wheel(s) and energy recovery wheel(s) to
check their operation.
Check that dampers are operating properly.
6
Check that the fan wheel(s) and energy recovery wheel(s) are rotating in the correct direction.
7
Adjust the fan motor VFD(s) to the correct air volume/Hertz.
For occupied recirculation mode, adjust outside, exhaust and mixed or recirculation air damper
positioners to achieve the required air volumes.
Check amperage draw to each motor on each phase against motor nameplate FLA. If significantly
different, check ductwork static and/or take corrective action.
3
4
8
9
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
85
Serial Number:______________________________________
Table E2: Start-up Checklist
20
Checklist Item
Recheck the voltage at the disconnect switch against the nameplate and against phase-to-phase
readings on three-phase with all blowers operating. If the voltage is not within 10% of rated or 2%
of phase-to-phase have the condition corrected before continuing start-up.
Before activating the compressor on WSHP units, check that the water shut-off valves are open and
water is circulating through the water-to-refrigerant heat exchanger. Check the incoming line water
pressure to ensure is within design and acceptable limits.
Enable the cooling mode of operation. Check if the sound of the compressor is normal or if there is
excessive vibration.
On units with integrated air cooled condensers check condenser fans are rotating in the correct
direction.
Check all field and factory refrigerant and water piping connections for leaks and correct.
Operate the refrigerant system near full load conditions in both heating and cooling modes and
check sub-cooling and superheat against values in Appendix P, Table P1. If readings do not match,
adjust the refrigerant charge. Refer to Appendix P for information on adjusting the refrigeration
charge.
On units with WSHP, after a few minutes of operation:
a. Check the supply discharge temperature status on the keypad for cooling air delivery. Measure
the temperature difference between entering and leaving water. In cooling mode, the temperature difference should be approximately 1.5 times greater than the heating mode temperature
difference. For example, if the cooling temperature difference is 15°F [8.3°C], the heating
temperature difference should be approximately 7°F to 10°F [3.9°C to 5.6°C]. Alternatively, if a
flow measuring valve or pressure gauge connections are included, take the flow reading or pressure drop compared to the submittal information and adjust the shut-off/balancing valve in the
return line to the correct flow/pressure drop reading.
b. Measure the temperature difference between entering and leaving air and entering and leaving
water. With entering water of 60°F to 80°F [15.6°C to 26.7°C], leaving temperature should
rise through the unit. Should not exceed 35°F [19.4°C]. If the air temperature exceeds 35°F
[19.4°C], then the water flow rate is inadequate or the airflow rate may be low and a second
check may be required after air flow balancing.
On units with gas-fired furnace module or electric heating coils, check supply air proving interlock
switch setting to ensure minimum supply airflow prior to burner operation. Set the switch to open
below the minimum supply airflow on the furnace rating plate.
Enable heating options, see start-up and check out instructions in Appendix D for gas-fired furnace
module and Appendix G for electric coil and complete.
For electric heating coil option check the amp draw on each stage, the operation of the sequence
or SCR controller and the coil for any hot spots.
Check the operation of the control options provided on the unit.
21
Check the setpoints on the DDC Points Reference, adjust and record changes as required.
22
Has air balancing been completed for both occupied and unoccupied operation?
When unit has achieved steady state, take measurements and complete Start-up Readings portion
of the Start-up Report and Checklist in Appendix E. Send a copy of the completed Start-up Report
and Checklist to Venmar CES to validate warranty. Maintain a copy of the report at the unit for
future reference.
Once completed, return setpoints to original or required values, return the unit to the correct mode
of operation and adjust the time clock if required.
10
11
12
13
14
15
16
17
18
19
23
24
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Check √
N/A
86
Serial Number:______________________________________
Start-up Readings
•
•
Allow unit to reach steady state before taking readings.
Complete based on options included with unit
Nameplate voltage
Input voltage
L1–L2
L2–L3
L1–L3
Table E3: Start-up Readings – Supply Fan
Rotation
Correct
Full Load Amps
(Nameplate Amps)
Amp Draw
L1
L2
L3
O/L Amp
Setting
Hertz
RPM
L3
O/L Amp
Setting
Hertz
RPM
Fan 1
Fan 2
Fan 3
Fan 4
Fan 5
Fan 6
Fan 7
Fan 8
Fan 9
Fan 10
Fan 11
Fan 12
Table E4: Start-up Readings – Exhaust Fan
Rotation
Correct
Full Load Amps
(Nameplate Amps)
Amp Draw
L1
L2
Fan 1
Fan 2
Fan 3
Fan 4
Fan 5
Fan 6
Fan 7
Fan 8
Fan 9
Fan 10
Fan 11
Fan 12
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
87
Serial Number:______________________________________
Table E5: Start-up Readings – Condenser Fan
Rotation Correct
Amp Draw
Full Load Amps
(Nameplate Amps)
L1
L2
L3
O/L Amp Setting
Fan 1
Fan 2
Fan 3
Fan 4
Fan 5
Fan 6
Fan 7
Fan 8
Fan 9
Fan 10
Fan 11
Fan 12
Fan 13
Fan 14
Fan 15
Fan 16
Table E6: Start-up Readings – Compressors
Full Load
Amps
(Nameplate
Amps)
Amp Draw
L1
L2
L3
After compressor has been running for 15 minutes check the
following:
Outdoor
Hot Gas Ambient Temp.
Suction Discharge
Liquid
During AC
Superheat
Bypass
Pressure Pressure
Subcooling
Cooling
Functioning
Start-up (°F/°C)
Compressor 1
Compressor 2
Compressor 3
Compressor 4
Compressor 5
Compressor 6
Compressor 7
Compressor 8
Compressor 9
Compressor 10
Compressor 11
Compressor 12
Compressor 13
Compressor 14
Compressor 15
Compressor 16
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
88
Serial Number:______________________________________
Table E7: Start-up Readings – WSHP
Waterside Cooling Mode
Entering
Leaving
Temp.
Temp.
Temp.
Difference
(°F/°C)
(°F/°C)
(°F/°C)
Entering
Temp.
(°F/°C)
Leaving
Temp.
(°F/°C)
Waterside Heating Mode
Temp.
Entering
Leaving
Difference Pressure
Pressure
(°F/°C)
(PSI)
(PSI)
US GPM
Condenser 1
Condenser 2
Condenser 3
Condenser 4
Condenser 5
Condenser 6
Condenser 7
Condenser 8
Condenser 9
Condenser 10
Condenser 11
Condenser 12
Condenser 13
Condenser 14
Condenser 15
Condenser 16
Table E8: Start-up Readings – Electric Heating Coil
Stage
L1 Amps
L2 Amps
L3 Amps
Check for Hot Pots
1
2
3
4
5
6
Table E9: Start-up Readings – Energy Recovery Wheel (ERW)
Full Load Amps
(Nameplate Amps)
Amp Draw
L1
L2
L3
O/L Amp Setting
ERW 1
ERW 2
ERW 3
ERW 4
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
89
Serial Number:______________________________________
Table E10: Start-up Readings – Gas-fired Duct Furnace
Fuel
Combustion air fan
Induced draft fan motor
Low fire
High fire
Natural Gas
Propane
Rotation correct2
Full load amps (nameplate amps)2
Amp draw L1/L2/L32
O/L amp setting2
Rotation correct
Full load amps (nameplate amps)
Amp draw L1/L2/L3
O/L amp setting
Inlet gas pressure – ” w.c.
Regulator outlet pressure – ” w.c.
Manifold press – ” w.c.
Stack CO2 – %2
Stack O2 – %2
Net stack temperature – °F/°C2
Efficiency – %2
Flame signal – mA/VDC
Supply air inlet temperature – °F/°C
Supply air discharge temperature – °F/°C1
Supply air temperature rise – °F/°C
Inlet gas pressure – ” w.c.
Regulator outlet pressure – ” w.c.2
Manifold press – ” w.c.
Stack CO2 – %2
Stack O2 – %2
Net stack temperature – °F/°C2
Efficiency – %2
Flame signal – mA/VDC
Supply air inlet temperature – °F/°C
Supply air discharge temperature – °F/°C1
Supply air temperature rise – °F/°C
Furnace #1
Furnace #2
1.Measure downstream where temperature is even in duct.
2.For IG series drum and tube gas-fired duct furnace models only.
This unit has been checked out and started according
with the above procedures and completed forms and is
operating satisfactorily. After 24 hours of satisfactory operation shut down the unit and check all foundation bolts,
shaft bearings, drive set screws, valve train and terminals.
Tighten where required.
Additional Comments:
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Start-up
By_________________________________________________
Company Name_____________________________________
Date_______________________________________________
Email______________________________________________
Telephone__________________________________________
Email to tech support: venmarservice@venmarces.com
or Fax to: 819-399-2612.
90
Appendix F: HEPA Filter Installation
These instructions are for installing AAF HEPA filters (11½”
depth) into AAF HEPA holding frames. The holding frames
are available in multiple sizes and materials, but include
the PN series of 30619XX-XXX, where the X’s vary with
frame size and material. All frames, latches, extension
legs and filters are sold separately. Please read the entire
installation instructions before beginning the installation
process.
Install filters into the HEPA holding frames only after the
frames have been securely installed into existing ductwork or housing. Frames should be bolted or pop riveted
together into the permanent structure through the predrilled holes around the outside perimeter of the frames.
Frames should be sufficiently caulked and sealed to prevent any air bypass or leakage.
Required Tools for Filter Installation
• T-handle Hexkey, size 5/32”
Framing Components Required
• AAF HEPA holding frames – PN 30619XXXXX
• Leg extensions, four per frame – PN 3061991- 00X
• Latches, four per frame – PN 3062007-00X
Figure F3: Frame with leg extensions installed
Step 2
Insert the HEPA filter into the HEPA holding frame. The
HEPA should be installed with the gasket side of the filter
facing the frame. Insert the filter as far into the frame
as possible, so that the gasket material is contacting the
frame. See Figure F4 below.
Figure F1: Leg extensions and latches
Step 1
At the inside corner of each frame are four tabs, two per
side. Place a leg extension over the four tabs as shown in
Figure F2 below, then pull back on the leg extension locking it into place.
Figure F2: Place leg extensions over the frame tabs, then
pull back to lock the leg extension into place
Figure F4: Insert HEPA filter into frame, until the gasket
comes in contact with the holding frame
Repeat Step 1 with each of the four corners. The frame
with leg extensions should look like Figure F3.
The filter should now be resting inside of the holding
frame as shown to the left. When installing the filters into
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
91
a frame bank of multiple frames, install the lower filters
first so that the upper filters can rest on the lower filters.
Step 4
Once all four corner latches have been tightened within
¼” of the leg extension coupling, complete the installation
by tightening each corner until the latch and leg extension
coupling meet. This is illustrated in Figure F8.
Figure F5: Filter placed inside of frame
Step 3
Place a latch so that it overlaps the leg extension, as
shown below in Figure F6. Align the latch’s cap screw with
the threaded coupling on the end of the leg extension and
tighten using the hexkey. Tighten the cap screw until there
is an approximately ¼” gap between the latch and the leg
extension coupling as shown below in Figure F7. Repeat
this step with all four corners.
Figure F8: Tighten until latch and coupling meet
Once all four corners have been tightened the filter should
now be properly seated and sealed.
Repeat the process with all remaining filters working from
the bottom to the top.
Figure F6: Latch overlapping leg extension
Figure F9: Properly installed filter
Figure F7: Tighten cap screw to ¼” of the coupling
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
92
Appendix G: Electric Heating Coil and Controls Information
This electric heating coil module covered by this appendix is a component of a “Listed” product, subject to the
guidelines of application as designated by the Certifying
Agency and outlined in the appliance Manufacturer’s installation and operation instructions.
2 – Electrical Installation of Electric Coil Heaters
The information provided in this appendix applies to the
electric heating coil module, installed in the appliance and
to its operation, maintenance and service. Refer to the appliance manufacturer’s instructions for information related
to all other components.
2.2 Read Nameplate
1 – Mechanical Installation of Electric Coil
Heaters
Use only wires suitable for 167°F [75°C]. Wires shall be
sized according to the Canadian Electrical Code requirements. All wires must be brought in through knock-outs.
1.1 Handling
1.1.1Remove the shipping covers just before installation.
1.1.2Inspect the heater carefully and report any damage to the manufacturer.
Do not install a damaged heater.
1.2 Installation
Heater Position
1.2.1The axis of the duct must always be perpendicular
to the face of the heater.
1.2.2The heating elements must always be installed
horizontally.
Model SC or ST (Slip-in Type)
1.2.3 Cut an opening in the side of the duct.
1.2.4Slip the heater into the duct until the hole is completely covered by flanges around the heater.
1.2.5Fasten the heater to the duct with sheet metal
screws and seal openings with a suitable sealing
compound.
1.2.6If the heater is heavy, use additional hangers to
support the heater.
Model FC or FT (Flanged Type)
1.2.7Flange both ends of the duct outwards on three
sides to match the heater’s flanges.
1.2.8Fasten the heater to the duct with sheet metal
screws (for heavy heaters, use nuts and bolts and
additional hangers to support the heater).
1.2.9 Seal openings with a suitable sealing compound.
•
•
•
•
IMPORTANT
Do not install spray humidifiers upstream of duct.
Install it downstream instead.
Do not cover the control box with thermal insulating materials.
Use special air intake louvers of weatherproof construction for preheat duct heaters to avoid intake of
water or snow particles.
Make sure that motorized damper blades are not
blocked with snow or dirt. Inspect the dampers
regularly to ensure a suitable airflow.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
2.1 Disconnect Power Source
Disconnect all power sources before opening the control
box and working within.
Read the nameplate carefully and consult wiring diagram
before starting to wire.
2.3 Supply Wires
2.4 Disconnecting Means
Install a disconnect switch close to the heater according
to the code unless a disconnect switch is already built into
the heater.
2.5 Control Circuit Wiring
Use Class 2 wiring for control circuit connections to the
duct heater.
2.6 Magnetic Contactors
If magnetic contactors are mounted outside of the duct
heater, use only contactors approved for:
•
•
•
•
250,000 operations when controlled by auto-reset
thermal cut-out (A) and by other switching devices in
series with this cut-out (thermostat, step controller,
airflow switch, etc.).
100,000 operations when controlled by auto-reset
thermal cut-out (A) alone.
100,000 operations when controlled by auto-reset
thermal cut-out (A) plus manual reset cut-out in series (A & M).
6,000 operations when controlled by manual reset
cutout (M) alone.
2.7 External Controls Ratings
Rating of external control devices shall be suitable for handling the VA ratings as marked on the nameplate; otherwise, a backup relay must be used.
2.8 Airflow Interlock
Heaters are generally supplied with one extra terminal
marked for fan interlock or air sensing device connection.
Remove jumper between terminals I and C before connecting the fan interlock. Select a suitable airflow sensing
device of the differential pressure sensing type, with snap
acting contacts. A slow make, slow brake device may
cause undue cycling and in some instances chattering of
the contactors. When fresh air dampers are used, make
sure the heater is properly interlocked to prevent it from
being energized before the damper is fully open.
93
3 – Operating Electric Coil Heaters
4.2 Electrical Inspection
3.1 Minimum Airflow
Two weeks after start-up, all electric connections to contactors should be checked and tightened up. Before each
heating season, check the resistance between the heating
elements and ground. It is also recommended to check
the electrical connections to heating elements, magnetic
contactors and main power lugs. This inspection is recommended monthly during the first four months of operation.
After that, two inspections per heating season are sufficient.
Ensure that sufficient airflow as marked on the nameplate
is passing through the heater. Airflow should be evenly distributed across the entire face of the heater. Use air turning
vane at duct elbows and splitter damper at duct branchoffs to streamline the airflow in the heater. Use suitable
airflow sensing device or interlock the heater with fan. An
insufficient airflow will lead to the opening of the autoreset thermal cut-out or damage to the heating elements.
3.2 Warning
The air flowing through the duct where the heater is installed shall not contain any combustible particles, nor any
flammable vapor or gas.
3.3 Air Temperature
The air temperature should not exceed 120°F [49°C] at the
heater outlet.
3.4 Minimum Static Pressure and Air Direction
The heater is protected by a differential pressure switch.
To keep the contact of this switch closed, it is necessary to
maintain a minimum total pressure of 0.07” of water for a
constant flow.
3.5 Manual Reset Thermal Cut-out
This protection device is standard on all heaters of less
than 300 volt and 30 kW and is optional on all other heaters. Please check the auto-reset thermal cut-out before
resetting the manual thermal cut-out. If any defect has
been detected in the auto-reset thermal cut-out, it will be
necessary to replace it before resetting the manual reset
thermal cut-out.
4.3 Checkpoints
•
•
•
•
•
Check all fuses.
Check the resistance to ground for each circuit.
Check the resistance phase-to-phase for each circuit.
Check the tightening of connections at all contactors
and heating elements.
Check all contactors.
4.4 Off-season Maintenance
Where tubular heating elements are used, it is strongly
recommended that you start the heating system from
time to time. This precaution will prevent moisture from
percolating through the terminal gaskets into the heating element and accumulating in the insulating powder.
Should a heater be shut off for a long period, we recommend that you check carefully the resistance to ground for
each circuit. It is important not to power a heater when
too low a resistance to ground has been measured. It is
also recommended to pay attention to any other heater
operating in normal conditions. Control components such
as step controllers or modulating valves (SCR) should be
maintained and checked according to respective Manufacturer’s instructions. Any defective components should be
replaced only with identical original parts.
4 – Maintenance
All electric coil heaters have been designed to operate
long term without problems. Those responsible for equipment and maintenance should be aware of the following
suggestions.
4.1 Visual Inspection
It is strongly recommended to complete a periodic inspection. This precautionary step will help to keep your installations operating well. Note these eventual first signs of
problems:
•
•
•
Accumulation of dust on the heating elements.
Signs of overheating on the heater frame.
Traces of water or rust on the control box.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
94
Appendix H: Extended Dormant Unit Maintenance Procedure
The following procedures must be applied to any unit
which is stored for a period exceeding one month, which
are required in order to maintain our warranty. Failure to
comply with the procedures outlined below may result in
damage and will void unit warranty.
1. Unit must be stored indoors in a clean, dry and tempered environment, heated in the winter and air
cooled in the summer. Ambient air conditions should
be from 50°F to 75°F with % RH from 10% to 50%.
The unit needs to be stored in a warehouse (or some
type of enclosure). Storing units outdoors is contraindicated and will void our warranty.
2. Unit must be stored on a level surface with the
weight of the equipment evenly distributed through
its base. The unit location must be free from excessive vibration and accidental impacts.
3. Once the unit has been unloaded in its resting location, the plastic wrapping must be removed from the
unit by cutting along the corner edges in order to
perform proper inspections and maintenance on the
equipment. The plastic wrapping should be kept and
re-applied to the unit when the unit will finally be
shipped to the jobsite.
4. If applicable, a certified/qualified Refrigeration
Technician should record refrigerant pressures on
all compressors at time of storage. Each compressor
must maintain refrigerant pressure in the system.
5. If applicable, a certified/qualified Refrigeration
Technician should check refrigerant pressure in
each compressor every three months. Refrigerant
pressure must be maintained in the system. If zero
pressure is found, this indicates a leak in the system.
Leak(s) must be identified and repaired. A holding
pressure must then be reinstalled.
•
•
IMPORTANT
Complete the Extended Dormant Unit Maintenance
Checklist below, send a copy to Venmar CES service
department at the below email address or fax every
six months and when unit is put into service, to validate warranty and to provide valuable information
to personnel performing future maintenance or for
factory assistance.
Leave a copy of this report with the owner and at
the unit for future reference and permanent record.
Additional Comments:_ ______________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
6. Rotate blower impellers by hand every two months;
grease fan bearings as required following proper
practices. Do not over grease the bearings as this
may rupture the seals and lead to premature bearing
failure during operation.
7. Rotate the energy recovery wheel rotor by hand once
per month.
8. Ensure that all unit doors are kept closed.
9. Continue above maintenance schedule until unit
start-up.
For all checks listed above please complete the Extended
Dormant Unit Maintenance Checklist below and send a
copy to the Venmar CES service department every six
months and when unit is put into service.
If the unit has been dormant for an extended period after
initial start-up, all start-up checks should be repeated before operating the unit. Refer to the EnergyPack Start-up
Report and Checklist in Appendix E and complete these
checks. Failure to comply with the above recommendations may result in component failure and surface corrosion on the interior and exterior of the unit.
Please note that if the unit is being stored outdoors or
remains dormant for an extended period after initial startup, this may result in condensation within the unit which
could result in premature degradation of the unit and
potential issues within the control panel. In this event, the
installation of a desiccant pouch in the control cabinet
is highly recommended; all ventilation ducts should be
capped/covered to prevent chimney effect, all liquid pipes
(water or glycol mixture) should be drained or capped
off if necessary and all peripheral electrical penetrations
should be properly sealed.
Email to tech support: venmarservice@venmarces.com
Fax: 899-319-2612
Unit Identification Information
Project_____________________________________________
Job Name__________________________________________
Job Address_ _______________________________________
Model Number______________________________________
Serial Number ______________________________________
Tag_ ______________________________________________
Jobsite Contact_ ____________________________________
Email______________________________________________
Telephone__________________________________________
Maintenance
By_________________________________________________
Company Name_____________________________________
Date_______________________________________________
Email______________________________________________
Telephone__________________________________________
95
Serial Number:______________________________________
Table H1: Extended Dormant Unit Maintenance Checklist
Item
Description
Yes
No
Is the unit stored indoors in a clean, dry environment?
1
Is the unit storage facility temperature regulated to within 50°F to 75°F?
2
Is the indoor storage facility humidity regulated to within 10% to 50% RH?
Is the unit mounted on a level surface along the perimeter of the base with weight evenly
distributed?
Has the plastic wrapping been removed from the unit to perform inspection and maintenance?
Has the plastic wrapping been saved for future use?
Has the plastic wrapping been re-applied to the unit when the unit has been shipped to
jobsite?
Recommend Has a desiccant pouch been placed in the control panel?
3
Item
Description
Refrigerant pressure at
storage
Compressor 1
Inspection Date/Reading
Date
PSIG
Compressor 2
Compressor 3
Compressor 4
Compressor 5
Compressor 6
Compressor 7
4
Compressor 8
Compressor 9
Compressor 10
Compressor 11
Compressor 12
Compressor 13
Compressor 14
Compressor 15
Compressor 16
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
96
Serial Number:______________________________________
Table H1: Extended Dormant Unit Maintenance Checklist
Item
Description
Refrigerant pressure
every three months
Compressor 1
Yes
No
Date
PSIG
Date
PSIG
Date
PSIG
Date
Date
Date
Date
Date
Date
Date
Date
Date
Date
Date
Date
Compressor 2
Compressor 3
Compressor 4
Compressor 5
Compressor 6
Compressor 7
5
Compressor 8
Compressor 9
Compressor 10
Compressor 11
Compressor 12
Compressor 13
Compressor 14
Compressor 15
Compressor 16
Rotate blower impellers every two months
Supply
Exhaust
6
Other
Grease fan bearings as
required
Supply
Exhaust
7
Other
Rotate energy recovery
rotor every one month
Enthalpy
Sensible
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
97
Appendix I: EnergyPack®, ERV5000–10000 and HRV3000–10000
Maintenance Summary Chart
Table I1: Maintenance Summary Chart – EnergyPack, ERV5000–10000, HRV3000–10000
Item
General
Fans
No. Description
Note
Monthly Quarterly
1
Inspect the general condition of the unit.
x
2
Remove any dirt or debris.
x
3
Check for unusual noise or vibration.
x
4
Lubricate the door latch mechanisms.
5
Clean fans with stream of water.
x
6
Align or replace belts and drives.
x
7
Adjust belt tension.
x
8
Check motor voltage and current.
x
9
Lubricate the motor and shaft bearings.
x
x
10 Lubricate motor base adjusting screws.
Dampers
x
11 Visual inspection for dirt or leakage.
x
12 Lubricate damper linkage.
x
13 Clean and replace prefilters.
Air filters
SemiAnnually
annually
x
14 Clean and replace final filters.
x
15 Inspect holding frames/sliding rack.
Coils
16 Clean the coils.
Plate heat
exchanger
Burner
x
17 Winterize the water coil.
18 Verify that the wheel is rotating freely.
Wheel
x
x
x
19 Lubricate bearings.
x
20 Inspect bearing bolts.
x
21 Tighten bearing set screws.
x
22 Tighten motor bolts (inspect one month after start-up).
x
23 Inspect seals (inspect one month after start-up).
x
24 Inspect belt.
Inspect media, rim, spokes and shaft (inspect one month after
25
start-up).
26 Inspect the general condition of the plate heat exchanger.
x
27 Measure pressure drop across the plate heat exchanger.
x
x
If needed
28 Inspect the burner area for hazardous material.
x
29 Inspect the stack.
x
30 Inspect condensate drain connections and disposal system.
x
31 Clean and recalibrate all controls.
x
32 Inspect the gas piping.
x
33 Inspect burner motor (or every 500 hours, whatever comes first).
x
34 Verify all electrical connections, tighten if necessary.
x
Electric
35 Verify all fuse holders.
x
36 Verify all motor overload settings.
x
Condenser
fans
37 Inspect fan blades for cracks.
x
38 Inspect for wear and tension.
Look for oil on all refrigeration components (including coils, com39
pressors, etc.) to indicate a refrigerant leak.
40 Verify for proper superheat.
Verify each circuit refrigerant site glass when the circuit is operat41 ing under steady state, full load conditions. It should be full and
clear. If not, look for refrigerant leaks.
x
Cooling
section
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
x
x
x
98
Appendix J: Measuring and Adjusting V-belt Tension
Table J1: Measuring V-belt Tension
V-belt Cross Section
Recommended Deflection Force (lbs)
Small Sheave Diameter
Range (Inches)
Initial Installation
3.0 to 3.4
3.6 to 4.2
4.6 to 6.0
4.6 to 5.4
5.6 to 7.4
8.6 to 9.4
7.0 to 8.5
9.0 to 12.0
13.0 to 16.0
12.0 to 15.5
16.0 to 18.0
22.0 to 27.0
17.7 to 23.6
23.7 to 31.5
31.6 to 39.6
2.1 to 3.4
3.6 to 4.2
4.6 to 6.0
3.7 to 5.4
5.6 to 7.4
8.6 to 9.4
5.8 to 8.5
9.0 to 12.0
13.0 to 16.0
2.65 to 3.35
3.65 to 4.12
4.5 to 5.6
6.0 to 10.6
7.1 to 8.5
9.0 to 11.8
12.5 to 16.0
12.5 to 16.0
17.0 to 20.0
21.0 to 24.8
2.20 to 3.35
3.65 to 4.12
4.50 to 5.60
6.00 to 10.60
4.4 to 8.5
9.0 to 11.8
12.5 to 16.0
3.3
3.5
3.7
6.0
6.3
6.6
13.2
13.9
14.6
26.5
27.8
29.1
39.7
41.7
43.7
4.4
4.6
4.9
7.7
8.2
8.6
17.2
18.1
19.0
5.5
6.4
7.5
8.6
19.2
23.3
27.3
50.9
57.1
61.3
5.5
6.4
7.5
8.6
19.2
23.3
27.3
A
B
C
D
E
AX
BX
CX
3V
5V
8V
3VX
5VX
Plunger with
deflection force scale (lbs)
Body with deflection
distance scale (inches)
Retensioned
Maximum
2.9
3.1
3.3
5.1
5.5
5.7
11.5
12.1
12.6
22.9
24.3
25.6
34.4
36.2
37.9
3.7
4.0
4.2
6.6
7.1
7.5
15.0
15.7
16.5
4.8
5.7
6.6
7.5
16.7
20.3
23.8
44.3
49.8
53.3
4.8
5.7
6.6
7.5
16.7
20.3
23.8
Minimum
2.2
2.4
2.5
4.0
4.2
4.4
8.8
9.3
9.7
17.6
18.7
19.6
26.5
27.8
29.1
2.9
3.1
3.3
5.1
5.5
5.7
11.5
12.1
12.8
3.9
4.4
5.1
5.7
13.0
15.6
18.5
34.4
38.6
41.4
3.9
4.4
5.0
5.7
13.0
15.6
18.5
Belt Sp
an
Deflec
tio
n
Force
Small O-ring
Large O-ring
Figure J1: Belt tension adjustment
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
99
Appendix K: Energy Recovery Wheel
Multi-link Drive Belt Instructions
How to Measure, Assemble and Install
How to Measure
Pull belt tight around sheaves to
check hand tight length, overlapping the last two tabs with two
holes in matching links as shown.
Count the number of links and
remove one link for every 24 of
Figure K1: Multi-link
O/3L, A/4L and B/5L sections,
and one link for every 20 of C and drive belt
D sections. This gives the correct
installed belt length and will ensure optimum belt tension
when running.
IMPORTANT
Every tenth link is designated with an arrow (←). For
multiple belt drive, ensure that each belt has the same
number of links.
Disassembly
1. Hold belt upside down. Bend back as far as possible;
hold with one hand. Twist one tab 90° parallel with
slot.
2. Pull end of link over tab.
3. Rotate belt end with tab 90°.
4. Pull belt end through two links.
2. Place end tab through two links at once.
3. Flex belt further and insert second tab through end
link by twisting tab with thumb.
4. Ensure tab returns to position across belt. Reverse
belt so tabs run inside.
IMPORTANT
Turn belt inside out (as shown) to ensure easy assembly
and disassembly.
Installation
1.
2.
3.
4.
5.
Turn belt with tabs to the inside before installing.
Determine direction of drive rotation.
Align belt directional arrow (←) with drive rotation.
Fit belt in nearest groove of smaller sheave.
Roll belt onto larger sheave, turning the drive slowly.
Belt may seem very tight; this is okay. Do not jog
motor.
6. Check to see all tabs are still in their correct position
and are not twisted out of alignment.
7. For multiple belt drives, work belt from groove to
groove. On particularly wide drives, it may be easier
IMPORTANT
With drive ratios around 1:1, it may be necessary to add
back one link to allow belts to be rolled on. This does not
apply if using Alternative Installation Method.
to install half the belts from the inboard side and half
from the outboard.
Alternative Installation Method
Figure K2: Disassemble multi-link drive belt
Assembly
1. Hold belt with tabs pointing outward.
1. Set motor in mid position of adjustment range and
mark base clearly.
2. Determine required belt length as described in How
to Measure section.
3. Push motor forward to minimum center distance.
4. Install belts as in Installation section.
5. Pull motor back to previously marked mid position.
Retensioning
Like all high performance V-belts, PowerTwist Plus V-belts
require the maintenance of correct drive tension to operate efficiently. Experience indicates that drive tension
should be checked after 24 hours running at full load. A
retension may be necessary depending on the severity of
the drive. Any initial belt stretch is then taken up. Subsequently, belt tension should be checked periodically and
adjusted when necessary.
Figure K3: Assemble multi-link drive belt
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
100
Appendix L: Fan Bearing Lubrication Schedule
Table L1: Recommended Grease Quantity
Shaft Size
Inches
Maximum Grease Capacity of Bearing Chamber
Millimeters
Ounces
Kilograms
0.50 to 0.75
13 to 19
0.125
0.004
0.875 to 1.187
25 to 31
0.375
0.011
1.25 to 1.50
32 to 38
0.625
0.018
1.687 to 1.937
43 to 49
0.875
0.025
2.00 to 2.437
51 to 62
1.250
0.035
2.50 to 2.937
63 to 75
2.000
0.056
3.00 to 3.437
76 to 87
3.500
0.098
3.50 to 4.00
89 to 102
6.000
0.168
4.187 to 4.937
106 to 125
10.000
0.280
Table L2: Generally Recommended Relubrication Frequency in Months
Operating Speed (RPM)
Up to 500
500–1,000
1,000–1,500
1,500–2,000
2,000–2,500
2,500–3,000
3,000–3,500
3,500–4,000
4,000–4,500
4,500–5,000
0.5–1.0”
[13–35 mm]
6
6
—
5
5
4
4
3
3
2
2
—
1.125–1.5”
[28–38 mm]
6
6
—
—
—
—
—
—
—
—
5
4
4
3
2
2
1
1
6
4
4
2
2
1
1
1
1
½
Bearing Shaft Size
1.625–1.937”
2.0–2.5”
[41–49 mm]
[50–63 mm]
6
6
6
4
6
5
4
2
5
4
2
2
4
3
1
1
3
2
1
1
2
1
1
½
2
2
½
—
1
—
½
1
—
—
—
—
2.687–3.187”
[68–81 mm]
5
4
4
2
3
1
2
1
1
½
2
½
3.437–3.937”
[87–100 mm]
4
4
3
2
3
1
1
½
—
½
—
—
—
—
—
—
—
—
—
Ball bearings
Roller bearings
All bearings are filled with grease before leaving the factory. Bearings may discharge through the seals when first started and run hotter for a short
period of time until excess grease is discharged. Do not replace the initial discharge.
Intervals assume a clean environment with a temperature range of 0°F to 120°F [−18°C to 49°C]. Lubricate more frequently under dirty conditions
and higher temperatures.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
101
Appendix M: FANWALL® Inlet Cone Alignment
Table M1: FANWALL Wheel/Cone Alignment Dimensions
Wheel Size
Backplate OD
Blade Width
Backplate Extension
Wheel/Cone Overlap
10
10.375
3.495
0.700
0.250
12
12.500
4.280
0.700
0.250
14
13.750
4.720
0.700
0.250
16
16.750
5.760
0.700
0.250
20
20.451
6.990
0.700
0.400
22
22.701
7.780
0.700
0.400
Blade width
(100% wide)
Backplate
extension
Wheel/cone
overlap
Backplate OD
Figure M1: FANWALL inlet cone alignment
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
102
Appendix N: Filter Resistance and Latches
Table N1: Prefilters
Depth
Nominal Size
2” [51 mm]
4” [102 mm]
Capacities (CFM)
Resistance @ Capacity (in. w.g.)
Medium
High
Medium
High
Final
12” x 24” x 2” [305 x 610 x 51 mm]
24” x 24” x 2” [610 x 610 x 51 mm]
500
1,000
1,000
2,000
0.08
0.08
0.28
0.28
0.90
0.90
12” x 24” x 4” [305 x 610 x 102 mm]
24” x 24” x 4” [610 x 610 x 102 mm]
600
1,200
1,200
2,400
0.12
0.12
0.36
0.36
0.90
0.90
Table N2: 12” [ 305 mm] Final Filters
Filter Efficiency
60–65%
80–85%
90–95%
Nominal Size
Capacities (CFM)
12” x 24” [305 x 610 mm]
24” x 24” [610 x 610 mm]
12” x 24” [305 x 610 mm]
24” x 24” [610 x 610 mm]
12” x 24” [305 x 610 m]
24” x 24” [610 x 610 mm]
1,000
2,000
1,000
2,000
1,000
2,000
Resistance (in. w.g.)
Initial
0.29
0.29
0.50
0.50
0.68
0.68
Final
1.5
1.5
1.5
1.5
1.5
1.5
Table N3: Filter Latches for Front or Upstream Access
Final Filter
1” nominal or single header
2” nominal
4” nominal
Prefilter
Latch
Venmar PN
None
C-70
207312240
2”
C-86
19516104
4”
C-89
19516106
None
C-70
207312240
2”
C-86
19516104
None
C-86
19516104
1”
Knock-on (4” + 1” or header)
500026047
2”
Knock-on (4” + 2”)
500026048
4”
Knock-on (4” + 4”)
None
12” nominal HEPA
12” double header
6” (M-pack) single header
2”
500026049
HEPA frame
VP-2
208290023
4”
VP-4
19516310
2”
C-80/VP-2
19516103 / 208290023
4”
C-80/VP-4
19516103 / 19516310
2”
C-70/C-86
207312240 / 19516104
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
103
Appendix O: Troubleshooting
Table O1: Troubleshooting – EnergyPack®, ERV5000–10000, HRV3000–10000
General
Symptom
Possible Cause
Air supply too cold.
Supply and exhaust air are unbalanced.
Noisy unit.
Bearings wear down
too quickly.
Blower wheel is rubbing on other parts.
Corrective Action
Check filters and enthalpy wheel for blockage. Balance flow
of supply and exhaust air so that exhaust air is equal or
greater than supply air. Install a post heat module.
Adjust wheel or replace defective part.
Blower wheel is out of alignment.
Remove the motor/blower assembly. Adjust the blower wheel.
Sheaves are out of alignment.
Verify wheel alignment. Align belt using a straight edge.
Enthalpy wheel wiper seal is not properly installed.
Check for proper seal operation.
Excessive belt tension causes bearings to screech.
Adjust belt tension.
Low belt tension causes belts to squeal.
Adjust belt tension.
Ducts are vibrating.
Install flexible connections.
Unit is too close to occupants.
Install a silencer.
Excessive vibration.
Replace shaft and bearings. Verify wheel alignment.
Belt too tight.
Adjust belt tension.
Balance flow of supply and exhaust air so that exhaust air is
equal to or greater than supply air.
Verify damper actuator operation.
Supply and exhaust air are unbalanced.
Defrost damper is not working.
Wheel freezing.
Pre-heater is not working.
Time between defrost cycle is too long.
Thermostat set too low for preheat or variable wheel
speed frost prevention systems.
Fan wheel is turning the wrong direction.
Rotation speed is too low.
Poor airflow.
Filters are blocked.
Air leakage.
Electric tension of motor is too low/high.
Seal all leaks in ducts and unit walls.
Verify pressure drop of both airflows and compare to the
submittal. Contact Venmar CES if a significant difference is
noted.
Adjust belt tension.
Verify presence of filters and other duct components. Set
balancing damper so that it reduces the passage of air.
Adjust tension.
Excessive fan speed.
Reduce blower speed.
Low motor power.
Unit equipped with recirculation defrost system is in
defrost mode.
A wire is disconnected.
Install more powerful motors.
Exchanger does not perform as per submittal.
Fan belt is slipping.
Low static pressure.
Fan motor overload.
Exhaust fan not
working.
Wait until the defrost cycle is over.
Drive motor failure.
Connect the wire.
Check unit circuit breaker. Verify wire service connector on
the motor.
Check the capacitor connections. Check the motor operation with a new capacitor.
Verify the drive motor operation.
Drive motor relay in control box.
Check relay wiring. Verify relay operation.
Drive belt failure.
Check for drive belt derailment or failure.
Drive pulley failure.
Check for securely fastened pulley on motor shaft.
Electrical supply is interrupted.
Drive motor capacitor failure (in small units only).
Wheel not running.
Check the heat module circuit breaker.
Shorten defrost cycle period by modifying the delay setpoint on DDC.
Set thermostat at a higher defrost setting by modifying the
defrost setpoint on the DDC. See Controls section of this
manual.
Reverse rotation or motor so that wheel turns in the direction of the arrows shown on the fan.
Increase speed by increasing the diameter of motor sheave
or installing a smaller fan sheave.
Replace filters.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
104
Table O1: Troubleshooting – EnergyPack®, ERV5000–10000, HRV3000–10000
General
Symptom
Possible Cause
Filters are too dirty and have been sucked into the
unit.
Filters are out of filters Filters are wet.
rack.
Filter rack is damaged.
Some filter clips are missing.
Corrective Action
Clean or change the filters and consider revising maintenance schedule.
Water infiltration or condensation. See Water Issues section
below.
Repair filter racks and re-install filters.
Order new clips from Venmar CES.
Water Issues
Airflow is too high.
Water carryover from
wet cooling coil onto Drain pan not properly draining.
the floor, motor or fan
Coil bulkhead penetration.
housing.
Missing or improper intermediate drain pan.
Unit was not properly sealed when installed.
Water inside the unit.
Electrical or piping conduits not properly sealed.
Trap is not properly installed.
Drain pan not properly Unit is not installed on level.
draining.
Pressure exceeds the design.
Prefilter is wet.
Solenoid valve does
not open.
Too much refrigerant
is being fed to the
evaporator and the
superheat is too low
(cannot be adjusted).
Lower airflow by adjusting the drive.
Clean drain pan and ensure suction into the unit is not too
high.
Be sure any field penetrations are sealed.
Install or clean the intermediate drain pan.
Seal all section joints. Sections under negative pressure require special attention to sealing.
Inspect and seal any holes made for electrical wires or piping conduits.
Revise trap installation and dimensions.
Revise the level of curbs.
Verify design pressure versus unit pressure and check the
segment which houses the drain pan.
Outside air hood is shipped loose and was not well
Reinstall hood, ensuring the flange is properly sealed.
sealed when installed.
Airflow exceeds design conditions and sucks water
Redesign the hood or lower the cfm of the unit.
into the unit.
Refrigerant Issues
No power to coil.
Check circuit connections.
Defective solenoid coil.
Replace solenoid coil.
Dirt or foreign material lodged in thermostatic expanDisassemble valve, remove dirt and re-verify superheat.
sion valve.
Defective thermostatic expansion valve.
Insufficient fluid flow across condenser coil.
Condenser fan failure.
Compressors lock out High pressure control.
on high head pressure Service valve failure.
or run at higher than
design head pressure. Refrigerant overcharge.
Supply water temperature may be too high.
Water control valves not operating properly.
Condenser fan(s) short
Improperly set sequencing control.
cycling.
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
Replace thermostatic expansion valve.
Clean dirty condenser coil. Comb damaged fin surface with
fin comb. Tighten loose fan belt(s).
Verify fan rotation. Verify fan rpm. Check fuses. Verify overload. Check fan controls. Check for motor burnout.
Check for proper setting.
Discharge valve fully back sealed.
Verify condenser subcooling (15ºF [−9ºC]). If above 15ºF
[−9ºC], adjust charge based on maintaining suction pressure.
Verify water temperature rise entering and leaving unit to
determine if adequate water is flowing.
Verify and repair water control valves.
Set for correct pressure and differential.
105
Appendix P: Adjusting Refrigerant Charge
CAUTION
The Clean Air Act of 1990 bans the intentional venting
of refrigerant (CFCs and HCFCs) as of July 1, 1992. Approved methods of recovery, recycling or reclaiming must
be followed. Fines and/or incarceration may be levied for
non-compliance.
CAUTION
It is very important to make certain that the recycle or recovery equipment used is designed for R410a. The pressure of R410a refrigerant is approximately 60% greater
than that of R22. Pressure gauges require a range up to
800 psig high side and 250 psig low side. Recovery cylinders require a 400 psig rating.
Adjusting the refrigerant charge of a system in the field
must be based on determination of liquid sub-cooling and
evaporator superheat. On a system with a TXV liquid subcooling is more representative of the charge than evaporator superheat but both measurements must be taken.
Before Charging
1. Unit being charged must be at or near full load conditions before adjusting the charge.
2. Units equipped with hot gas reheat must be charged
with the hot gas reheat valves closed while the unit
is in cooling mode to get the proper charge. After
charging, unit must be operated in reheat (dehumidification) mode to check for correct operation.
3. Units equipped with heat pump options must be
charged in heating mode to get the proper charge.
After charging, unit must be operated in cooling
mode to check for correct charge. Charge may need
to be adjusted for cooling mode. If adjustments are
made in the cooling mode heating mode must be
rerun to verify proper operation.
4. After adding or removing charge the system must be
allowed to stabilize, typically 10-15 minutes, before
making any other adjustments.
5. The type of unit and options determine the ranges
for liquid sub-cooling and evaporator superheat.
Refer to Table P1 when determining the proper subcooling and superheat.
Checking Liquid Sub-Cooling
1. Measure the temperature of the liquid line as it
leaves the condenser coil.
2. Read the gauge pressure at the liquid line close to
the point where the temperature was taken. One
must use liquid line pressure as it will vary from discharge pressure due to condenser coil pressure drop.
3. Convert the pressure obtained to a saturated temperature using the R410a refrigerant temperature verses
pressure Table P2. Subtract the measured liquid line
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
temperature from the saturated temperature to determine the liquid sub-cooling.
4. Compare calculated sub-cooling to Table P1 for the
appropriate unit type and options.
Checking Evaporator Superheat
1. Measure the temperature of the suction line close to
the compressor.
2. Read gauge pressure at the suction line close to the
compressor.
3. Convert the pressure obtained to a saturated temperature using the R410a refrigerant temperature verses
pressure in Table P2.
4. Subtract the saturated temperature from the measured suction line temperature to determine the
evaporator superheat.
5. Compare calculated superheat to Table P1 for the
appropriate unit type and options.
Table P1: Acceptable Refrigeration Circuit Values
Air Cooled Condenser or Air Source Heat Pump
Sub-cooling
12–18°F
Sub-cooling with hot gas re-heat 15–22°F
Superheat
8–15°F
Water Cooled Condenser or Water Source Heat Pump
Sub-cooling
4–8°F
Superheat
8–15°F
CAUTION
Thermal expansion valve must be adjusted to approximately 8–15°F of suction superheat. Failure to have sufficient superheat will damage the compressor and void
the warranty.
Adjusting Sub-cooling and Superheat
Temperatures
1. The system is overcharged if the sub-cooling temperature is too high and the evaporator is fully loaded
(low loads on the evaporator result in increased subcooling) and the evaporator superheat is within the
temperature range as shown in Table P1 (high superheat results in increased sub-cooling).
2. Correct an overcharged system by reducing the
amount of refrigerant in the system to lower the subcooling.
CAUTION
Do not overcharge!
Refrigerant overcharging leads to excess refrigerant in
the condenser coils resulting in elevated compressor discharge pressure.
106
3. The system is undercharged if the superheat is too
high and the sub-cooling is too low
4. Correct an undercharged system by adding refrigerant to the system to reduce superheat and raise subcooling.
Table P2: R410a Refrigerant Temperature vs. Pressure
°F
PSIG
°F
PSIG
20
78.3
47
134.7
21
80.0
48
137.2
22
81.8
49
139.7
23
86.6
50
142.2
24
85.4
51
144.8
25
87.2
52
147.4
26
89.1
53
150.1
27
91.0
54
152.8
28
92.9
55
155.5
29
94.9
56
158.2
30
96.8
57
161.0
31
98.8
58
163.8
32
100.9
59
166.7
33
102.9
60
169.6
34
105.0
61
172.5
35
107.1
62
175.4
36
109.2
63
178.4
37
111.4
64
181.5
38
113.6
65
184.5
39
115.8
66
187.6
40
118.1
67
190.7
41
120.3
68
193.9
42
122.7
69
197.1
43
125.0
70
200.4
44
127.4
71
203.6
45
129.8
72
207.0
46
132.2
73
210.3
VCES-ASTON-IOM-1D – EnergyPack, ERV5000–10000, HRV3000–10000
°F
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
5. If the sub-cooling is correct and the superheat is too
high, the TXV may need adjustment to correct the
superheat.
PSIG
213.7
217.1
220.6
224.1
227.7
231.3
234.9
238.6
242.3
246.0
249.8
253.7
257.5
261.4
265.4
269.4
273.5
277.6
281.7
285.9
280.1
294.4
298.7
303.0
307.5
311.9
316.4
°F
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
PSIG
321.0
325.6
330.2
334.9
339.6
344.4
349.3
354.2
359.1
364.1
369.1
374.2
379.4
384.6
389.9
395.2
400.5
405.9
411.4
416.9
422.5
428.2
433.9
439.6
445.4
451.3
457.3
°F
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
PSIG
463.2
469.3
475.4
481.6
487.8
494.1
500.5
506.9
513.4
520.0
526.6
533.3
540.1
547.0
553.9
560.9
567.9
575.1
582.3
589.6
596.9
604.4
611.9
107
info@venmarces.com
www.venmarces.com
The Manufacturer has a policy of continuous improvement and reserves the right
to change design and specifications without notice. FANWALL TECHNOLOGY®
and FANWALL® are trademarks of Huntair, Inc. Products in this literature are covered by one or more of the patents listed on www.ces-group.com/patents.
©2008 Venmar CES Inc.
VCES-ASTON-IOM-1D
March 2014