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Energy Wall U-ERV 1200, Installation, Operation & Maintenance Manual

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Energy Wall U-ERV 1200 Installation, Operation & Maintenance Manual Download Page 10

 

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ENERGYWALL.COM

    INSTALLATION, OPERATION & MAINTENANCE MANUAL   717.814.5365     

 

U-ERV/U-HRV 

Once the curb is positioned and fastened in 

place, apply the supplied gasket around each 

flange as shown* 

 
 
 
 
 
 
 
 
 
 
 
 
 
 

 
 

*1800 system shown for reference

 

 

Place the first unit on the curb, over the duct 

flanges, as shown. 

In some instances, the fan 

cubes will be mounted underneath the unit 

as opposed to on top. This is acceptable.

 

 
 
 
 
 
 
 
 
 
 
 
 

 
 

 
 
 
 
 
 
 
 
 
 

 

Place the remaining units (if applicable). Fasten 

the 4 connecting bolts inside each access panel 

with the hardware provided as shown 

 
 
 
 
 
 
 
 
 
 
 
 
 
 

 
 

Once the system is in place, secure it to the curb duct 

flanges using #14 x 1.5” long self-drilling screws. A 

minimum of 4 screws must be used per unit (i.e. an 

1800 system requires at least 12 screws) 

 
 
 
 
 
 
 
 
 
 
 
 
 
 

 
 

 
 
 
 

 

 

INSTALLATION  

MECHANICAL 

– CURB MOUNT 

Summary of Contents for U-ERV 1200

Page 1: ...ENERGYWALL COM INSTALLATION OPERATION MAINTENANCE MANUAL 717 814 5365 Gen 4 REV 0 2 1 21 INSTALLATION OPERATION MAINTENANCE MANUAL ENERGY RECOVERY VENTILATORS ...

Page 2: ......

Page 3: ...ntation 7 Curb Mount 8 Intakes 9 10 Ductwork 11 13 Electrical 14 Electrical Ratings 14 System Wiring 15 Remote HMI 16 General Wiring Schematic 17 Operation 18 Start Up Procedure 18 System Commissioning 19 Menu Layout 20 21 Menu Descriptions 22 33 BACnet Modbus 34 41 Optional Features 42 Economizer Defrost 42 Auxiliary Damper 43 Auxiliary Heat 43 Performance 44 Airflow 44 47 Acoustic 48 Service Mai...

Page 4: ...RIC SHOCK HAZARD Disconnect all electric power sources prior to working on equipment Wear protective equipment per NFPA 70 before servicing the electrical cabinet Failure to comply may result in serious injury or death Before commissioning or servicing the system read through this entire document carefully and ensure all precautions are taken Verify system nameplate electrical requirements match u...

Page 5: ...cessary components are present and intact 4 Verify system is configured as ordered 5 Clear system of any debris Prior to placing the system 1 Ensure installation site is structurally sound and clear of any obstructions 2 Verify adequate service clearances 3 Position system in a way that reduces complex duct transitions 4 If mounting outdoors verify system inlet is positioned in accordance with loc...

Page 6: ...electrical cabinet wire plugs are removed using a 12mm Allen key blue perimeter gasketing is installed at the locations as shown red and 4 connecting bolts are installed in each quadrant green Repeat on all units except the final unit in the system Prior to stacking the secondary unit with the primary ensure the secondary unit electrical cabinet wire plugs are removed blue and receiving plugs w a ...

Page 7: ...ENERGYWALL COM INSTALLATION OPERATION MAINTENANCE MANUAL 717 814 5365 5 ENERGY WALLTM U ERV U HRV INSTALLATION GENERAL UNIT SPECIFICATIONS ...

Page 8: ...ubstituted with vertical leg assemblies Ensure minimum 1 5 clearance between Unistrut and system flanges to provide adequate duct mounting clearance Side View INSTALLATION MECHANICAL HORIZONTAL RAIL MOUNT Clamp system between 4 pieces of Unistrut as shown below with minimum 3 8 dia all thread Be sure to leave an additional slot on each end to hang the system DO NOT EXCEED 20 IN LBS OF TORQUE WHEN ...

Page 9: ...on each end to hang the system DO NOT EXCEED 20 IN LBS OF TORQUE WHEN CLAMPING THE SYSTEM Ensure minimum 1 5 clearance between Unistrut and system flanges to provide adequate duct mounting clearance Side View Hang system assembly at desired height using minimum 3 8 dia all thread When mounting the system on a pad 3 8 dia all thread can be substituted with vertical leg assemblies INSTALLATION MECHA...

Page 10: ...as shown In some instances the fan cubes will be mounted underneath the unit as opposed to on top This is acceptable Place the remaining units if applicable Fasten the 4 connecting bolts inside each access panel with the hardware provided as shown Once the system is in place secure it to the curb duct flanges using 14 x 1 5 long self drilling screws A minimum of 4 screws must be used per unit i e ...

Page 11: ... with motorized dampers are available upon request Slide the intake hood over the fan cube left or system flange right as shown below 1800 system shown for reference Ensure the intake hood s opening is flush with the horizontal surface of the system as shown Once the intake is in place secure it to the system flanges using 14 x 1 25 long self drilling screws on all 4 sides A minimum of 2 screws mu...

Page 12: ...Ensure the intake hood s opening is flush with the vertical surface of the system as shown Once the intake is in place secure it to the system flanges using 14 x 1 25 long self drilling screws on all 4 sides A minimum of 2 screws must be used per unit i e an 1800 system requires at least 6 screws per intake INSTALLATION MECHANICAL INTAKE HORIZONTAL MOUNT Acoustic lined Intake Standard unlined Inta...

Page 13: ... over the system flanges fan cube when applicable See next page for recommended duct connection details Minimum straight duct lengths prior to any elbow per the below table must be adhered to Additional length is recommended to mitigate sound within the space When installing duct from curb hangers ensure proper alignment of duct with system inlet discharge Gasket must be used to seal the duct flan...

Page 14: ...within the sides of the duct to allow the system to be easily serviced An example of each duct connection recommendation for an 1800 system is shown below A TO SERVICE A FAN WITHIN DUCT REMOVE DUCT 2 FOLLOWED BY DUCT 1 ENSURE DUCT 3 IS INDEPENDENTLY SUPPORTED AND DOES NOT RELY ON THE SYSTEM FOR SUPPORT B A WATER TIGHT ACCESS PANEL CAN BE INSTALLED IN THE LOCATION AND SIZE SPECIFIED WITHIN THE DUCT...

Page 15: ...and image below for duct hanger locations within the curb curb lid not shown System Size A IN B IN 600 17 5 13 75 1200 29 75 26 1800 42 38 25 2400 54 25 50 5 3000 66 5 62 75 3600 78 75 75 4200 91 87 25 4800 103 25 99 5 5400 115 5 111 75 6000 127 75 124 INSTALLATION MECHANICAL DUCT HANGERS 1 88 A B 60 13 15 5 3 25 1 38 ...

Page 16: ...208 277V 50 60 3 38 1 38 9 40 5400 208 277V 50 60 3 36 36 9 40 6000 208 277V 50 60 3 43 1 44 45 As standard all supply and exhaust fans utilize a state of the art electrically commutated motor ECM to directly drive a mixed flow wheel Fan specifications are listed below FAN DATA System Voltage Frequency Supply Fan Quantity Exhaust Fan Quantity Max Supply HP Max Exhaust HP Max Fan RPM 600 208 277V 5...

Page 17: ...View Bottom View To remove the threaded plug a 12mm Allen wrench is required Once removed a stress relief can be used to secure the wire run to the system Connect power wires to the disconnect and terminal blocks shown below in red and control wires if applicable to the terminal blocks and primary controller shown below in blue Detailed schematics will be provided per job WARNING BEFORE PROCEEDING...

Page 18: ...nd menu navigation from the space a remote human machine interface HMI can be used as shown below Typical HMI Wiring The HMI can be mounted in a standard junction box via the screw holes shown below All hardware required to physically mount the HMI is included INSTALLATION ELECTRICAL REMOTE HMI UP DOWN ENTER ESC BACK PROGRAM FAULTS ...

Page 19: ...ENERGYWALL COM INSTALLATION OPERATION MAINTENANCE MANUAL 717 814 5365 17 ENERGY WALLTM U ERV U HRV INSTALLATION ELECTRICAL GENERAL WIRING SCHEMATIC ...

Page 20: ...m all access panels are secured in place 6 Once steps 1 5 have been completed turn the disconnect to the ON position Most applications will be configured per job from the factory If new software is required or the controller needs to be programmed follow the System Commissioning instructions on page 14 of this document Once the system is powered it will begin an initialization sequence to identify...

Page 21: ...n the controller If the controller does not ask to install the upgrade file access the controller system menu by holding the Alarm and Enter buttons for two seconds then select the UPGRADE option The software file should be listed Once uploaded power cycle the system Ethernet Connect the controller into a network The network address settings for the device can be found by holding Alarm and Enter f...

Page 22: ...INTS FAN CONTROL SETPOINTS ECONOMIZER SETPOINTS DEFROST SETPOINTS FREEZESTAT SETPOINTS AUX HEAT SETPOINTS COIL MODE SETPOINTS OPERATIONAL SETTINGS SCHEDULE SETTINGS SET SCHEDULE A SET SCHEDULE B FAN MODE MANUAL PURGE CONFIG PURGE MODE PURGE DAMPER POSITION PURGE TIMER PURGE FAN SPEED ALARM MODE ALARM FAN MODE ALARM FAN SPEED FAN START TIME DELAY FAN STOP TIME DELAY COIL CONFIG COIL ACTIVATION COIL...

Page 23: ... SERVICE INTERFACE INPUTS DIGITAL INPUTS ANALOG INPUTS TEMPERATURES RELATIVE HUMIDITIES OUTPUTS DIGITAL OUTPUTS ANALOG OUTPUTS RESET FAULTS TEST MENU SUPPLY FAN SPEED EXHAUST FAN SPEED DIGITAL IO CONTROL ANALOG IO CONTROL ADMIN SETTINGS PID SETTINGS PRESSURIZATION PIDs CO2 PIDs COIL PIDs BYPASS FAN FACTOR DAMPER POSITION OFFSET RESET DEFAULTS UNIT ORIENTATION SYSTEM INFO JOB SYSTEM TAG SYSTEM SERI...

Page 24: ... is entered the user can manually enable or disable the system If the unit is controlled via BMS it will be noted as such within this menu SETPOINTS All adjustable setpoints that control how the unit operates can be found within this menu OPERATION MENU DESCRIPTIONS The following section briefly explains the function of each menu within software HOME SCREEN The home screen is the default screen wi...

Page 25: ...ine the damper bypass percentage by relating it to the economizer activation enthalpy the return enthalpy and the outdoor air enthalpy ECONOMIZER DISABLE TEMP The economizer disable temp will restrict the economizer from activating and also shut the economizer off while active when the outdoor air temperature drops below the economizer disable temp Used in both enthalpy and temperature economizer ...

Page 26: ...ATION TEMP The freezestat activation temp setpoint determine at what supply temperature the system will begin a freezestat timer Once the timer expires the system will shut down and display a manual reset fault on the HMI FREEZESTAT TIMER The freezestat timer is used when freezestat operation is enabled to determine how long the supply air temperature must consistently measure below the freezestat...

Page 27: ...ly and exhaust fans when the unit is enabled as defined below MANUAL When fan mode is set to manual the supply and exhaust fans will operate independently at fixed speeds as defined in the fan control setpoints menu when the system is enabled When scheduling is enabled an occupied and unoccupied setpoint can be set ANALOG When fan mode is set to analog and the system is enabled the supply and exha...

Page 28: ...be found within the fan control setpoints menu The PID loop settings can be found within the PID settings menu When scheduling is enabled occupied and unoccupied supply exhaust and CO2 PPM setpoints can be set PRESSURE When fan mode is set to pressure the supply and exhaust fans will modulate based on a PID loop to maintain a specific duct or building pressure IN W C as defined by a pressure set p...

Page 29: ...nd purge timer menus PURGE DAMPER POSITION The purge damper position sets the damper to run in full core bypass or no core bypass when manual purge mode is enabled PURGE TIMER The purge timer determines how long the manual purge feature runs for before expiring PURGE FAN SPEED The purge fan speed determines at what speed the supply and exhaust fan operate at when the manual purge feature is enable...

Page 30: ...ng down by a defined period after the system has been disabled COIL CONFIG All settings related to coil configuration are currently being developed and will be released in the next version of software ENABLED OPTIONS PW 56789 The enable options menu is a password protected menu that allows the user to enable disable or select the type of various control features Once a feature is enabled various s...

Page 31: ...an is running FREEZESTAT Enables or disables the freezestat feature COIL MODE The coil mode configuration is currently being developed and will be released in the next version of software FILTER ALARM MODE The filter alarm mode is currently being developed and will be released in the next version of software TEMP RH SENSORS Enables or disables temperature and relative humidity RH sensors within al...

Page 32: ...relative humidities read by the controller can be monitored here SERVICE OUTPUTS This menu is used to view all outputs into the system DIGITAL OUTPUT STATUS All digital outputs from the controller can be monitored here ANALOG OUTPUT STATUS All analog outputs from the controller can be monitored here RESET FAULTS When a critical fault occurs the fault can be manually reset via this menu TEST MENU V...

Page 33: ...ntroller can be toggled on off via this menu ANALOG OUTPUT CONTROL All 0 10VDC analog outputs from the controller can be toggled via this menu ADMIN SETTINGS PW 39255 The admin settings menu is a password protected menu that allows the user to access system settings unit configuration settings and various settings associated with core functionality of the system s logic PID SETTINGS All PID contro...

Page 34: ... air pressure the bypass fan factor is used to reduce the supply fan s speed when the damper bypasses the core DAMPER POSITION OFFSET Up to 10 dampers can have their position calibrated via the damper position offset Adjusting this value will independently zero any of the dampers within a system RESET DEFAULTS This menu resets all configuration settings and setpoints to the default values when sof...

Page 35: ...s will not operate as desired QUADRANT C FAN Quadrant C fan should be enabled if a fan is installed in quadrant C Note if the fan quadrants are not enabled properly fans will not operate as desired QUADRANT D FAN Quadrant D fan should be enabled if a fan is installed in quadrant D Note if the fan quadrants are not enabled properly fans will not operate as desired SYSTEM INFORMATION System specific...

Page 36: ...ers 00005 94 See the note on parameters that need to be saved using this coil Scheduled Operation Mode Enable 00006 126 Shutoff Damper Mode Enable 00007 127 Aux Heat Mode Enable 00008 128 Freezestat Mode Enable Enable 00009 129 Filter Alarm Mode Enable 00010 130 Reset Defaults 00011 131 Performs a factory Reset of the unit Metric UOM on HMI display 00012 132 Crossflow Orientation 00013 133 Fan in ...

Page 37: ...5 J11 5 10008 110 Relay 6 J12 1 and 2 10009 111 On indicates this relay is closed Input Registers read only values Name Modbus Address BACnet ID Format Description Fan Tachometers 30001 30040 17 56 16 bit signed integer Indicates the RPM of each possible fan If a fan is not present or operating RPM will be 1 See Fan Section Fault Status 30041 85 16 bit integer This is a bit field indicating any fa...

Page 38: ...t U6 30064 30065 99 Analog input U7 30066 30067 100 Analog input U8 30068 30069 101 Analog input U9 30070 30071 102 Analog input U10 30072 30073 103 Analog Output U1 30074 30075 112 The output Voltage in volts Analog Output U2 30076 30077 113 Analog Output Y1 30078 30079 114 Analog Output Y2 30080 30080 115 Bypass Fan Factor 30082 149 16 bit integer The system bypass supply fan factor in percent S...

Page 39: ...olding Registers read write numerical values Name Modbus Address BACnet ID Format Description Supply Fan Speed 40001 0 16 bit unsigned integer Indicates or sets the fan speed in percent 0 100 In BMS mode this sets the requested speed In other modes it gives the current commanded speed Exhaust Fan Speed 40002 1 Economizer Disable Temp 40003 40004 6 32 bit floating point Degrees C Economizer Activat...

Page 40: ...ng point Pressure Mode PID Ti Value 40024 40025 117 Pressure Mode PID Td Value 40026 40027 118 CO2 Mode PID Kp Value 40028 40029 119 CO2 Mode PID Ti Value 40030 40031 120 CO2 Mode PID Td Value 40032 40033 121 Aux Heat Temperature Set point 40034 40035 122 Degrees C Aux Heat Temperature Set point occupied 40036 40037 123 Aux Heat Temperature Set point Unoccupied 40038 40039 124 Aux Heat Temperature...

Page 41: ...nomizer Damper Mode 40050 146 0 Off 1 Temperature 2 Enthalpy Defrost Mode 40051 147 0 Off 1 Modulating Bypass 2 Modulating Fan Occupied Supply Fan Speed 40053 59 0 100 Occupied Exhaust Fan Speed 40054 60 Unoccupied Supply Fan Speed 40055 61 Unoccupied Exhaust Fan Speed 40056 62 Supply Fan Speed 40057 57 Exhaust Fan Speed 40058 58 Supply Fan Min Speed 40059 63 Supply Fan Max Speed 40060 64 Exhaust ...

Page 42: ...CO2 Unoccupied PPM Setpoint 40075 40076 77 Pressure Differential Setpoint 40077 40078 78 32 bit floating point Pascals Pressure Differential Occupied Setpoint 40079 40080 79 Pressure Differential Unoccupied Setpoint 40081 40082 80 Quadrant A Airstream 40083 160 16 bit integer 0 Outside Air 1 Supply Air 2 Return Air 3 Exhaust Air System Size 40084 161 0 600 CFM 5 3600 CFM 1 1200 CFM 6 4200 CFM 2 18...

Page 43: ...rt Minute End Hour End Minute Schedule A Monday 00019 226 40108 172 40109 173 40106 170 40107 171 Schedule A Tuesday 00020 227 40112 176 40113 177 40110 174 40111 171 Schedule A Wednesday 00021 228 40116 180 40117 181 40114 178 40115 179 Schedule A Thursday 00022 229 40120 184 40121 185 40118 182 40119 180 Schedule A Friday 00023 230 40124 188 40125 189 40122 186 40123 187 Schedule A Saturday 0002...

Page 44: ...defrost function is selected a bypass damper will be installed within the desired quadrant as shown below Temperature and relative humidity sensors will be required within each quadrant A digital encoder is used to verify damper position and ensure proper orientation during standard economizer and defrost operations Note A fan cube or fan cube support an empty fan cube is needed in the same quadra...

Page 45: ...45s to ensure dampers are open prior to moving air INTAKE HOOD WITH MOTORIZED AUXILIARY DAMPER EXAMPLE AUXILIARY DAMPER An auxiliary heater can be used in conjunction with the system to provide upstream or downstream heating to the supply airstream When enabled a dry contact on the primary controller will close when the provided shipped loose 10k thermistor reads a temperature below the auxiliary ...

Page 46: ...ed together and added to the External Static Pressure to determine each system s airflow capabilities For systems larger than 600 divide the desired CFM by 600 and round up to the nearest whole number to determine the number of units in the system Then divide the total number of units calculated by the desired CFM This resultant CFM is what should be used when reading each fan curve FAN FAN POSITI...

Page 47: ...NSTALLATION OPERATION MAINTENANCE MANUAL 717 814 5365 45 ENERGY WALLTM U ERV U HRV FAN FAN POSITION 5 FAN FAN POSITION 6 FAN FAN POSITION 7 FAN FAN POSITION 8 FAN FAN POSITION 9 FAN FAN POSITION 10 PERFORMANCE AIRFLOW ...

Page 48: ...46 ENERGYWALL COM INSTALLATION OPERATION MAINTENANCE MANUAL 717 814 5365 U ERV U HRV U ERV HRV 600 Fan Positions 5 8 U ERV HRV 600 Fan Positions 1 4 PERFORMANCE AIRFLOW ...

Page 49: ...WALL COM INSTALLATION OPERATION MAINTENANCE MANUAL 717 814 5365 47 ENERGY WALLTM U ERV U HRV U ERV HRV 600 Fan Positions 9 10 Optional Pressure Drops Add to Fan as External Static Pressure PERFORMANCE AIRFLOW ...

Page 50: ...ls with Insulated Ducting Fan Speed At 3ft At 10ft 0 25 25 10 25 25 20 25 25 30 31 8 25 40 35 1 25 50 38 7 28 2 60 48 5 38 70 53 7 43 2 80 54 7 44 2 90 55 8 45 3 100 56 0 45 5 Decibels without Ducting Fan Speed At 3ft At 10ft 0 25 25 10 41 7 31 2 20 56 3 45 8 30 59 3 48 8 40 61 50 5 50 62 1 51 6 60 64 9 54 4 70 69 1 58 6 80 71 5 61 90 72 8 62 3 100 73 6 63 1 PERFORMANCE ACOUSTIC ...

Page 51: ...se incorrect wiring Trace back power communication wires and verify wiring per electrical schematic Ensure there are no loose cables or wires Bad motor Replace fan cube Secondary unit s fan s are not operating Secondary unit wiring kit was never installed Wire per electrical schematic Loose incorrect wiring Trace back power communication wires and verify wiring per electrical schematic Ensure ther...

Page 52: ...ply fan exhaust fan temp RH sensors or secondary controller has occurred in unit 1 Automatic Unit 2 Comm Error A communication error to the supply fan exhaust fan temp RH sensors or secondary controller has occurred in unit 2 Automatic Unit 3 Comm Error A communication error to the supply fan exhaust fan temp RH sensors or secondary controller has occurred in unit 3 Automatic Unit 4 Comm Error A c...

Page 53: ...ilter or double 20 18 long filters in series can be used in each airstream Standard filters from the factory utilize 2 20 18 long filters per airstream Filter Quantity and Size Per System System Size Filter Size Total Filter Quantity 600 5 13 x 40 38 x 2 2 5 13 x 20 18 x 2 4 1200 5 13 x 40 38 x 2 4 5 13 x 20 18 x 2 8 1800 5 13 x 40 38 x 2 6 5 13 x 20 18 x 2 12 2400 5 13 x 40 38 x 2 8 5 13 x 20 18 ...

Page 54: ...NT SERVICE MAINTENANCE 1 2 3 4 5 6 7 8 To replace the filter simply remove the access panel shown below and slide the filter out of its track Depending on system configuration the access panel to remove the filter may vary locations from what is shown Side View Before taking any access panel off ensure the disconnect is turned to the OFF position If the optional rotary bypass damper is installed t...

Page 55: ...e unit s airstreams whenever the system is serviced Verify all access panels are properly secured and all fasteners are tightened to the required specifications Ensure there is no air leakage between fan cubes or ducting and verify any duct sealant is not dried or cracking Inspect all moving parts for obstructions or irregularities Correct as needed prior to restarting the system Inspect filters e...

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