ERV Vertical Unit Ventilators

Transcription

1 ERV Vertical Unit Ventilators Classroom Ventilators with Energy Recovery and Gas Heat Installation, Operation and Maintenance Instructions Manual Capacity: 800 to 1,200 cfm Model: ERV1100w with Gas Heat If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Important Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. What to do if you smell gas Do not try to light any appliance. Do not touch any electrical switch and do not use any phone in your building. Immediately call your gas supplier from a phone located outside the building. Follow the gas supplier s instructions. If you cannot reach your gas supplier, call the fire department. Installation and service must be performed by a qualified installer, service agency or the gas supplier Venmar CES Inc.

2 Table of Contents Nomenclature...3 Safety Considerations...4 Specifications...4 Installation...5 Requirements and Codes...5 Rough In...5 Power...6 Controls...7 Balancing...8 Ventilation/Recirculation Setting...8 Venting and Combustion Air Requirements...8 Venting Requirements...10 Conversion Kits...13 Gas Supply and Piping...13 A Coil Mounting...15 Electrical Wiring...16 System Operation...17 Start-up and Adjustments...17 Sequence of Operation...19 Sequence of Operation (ERV1100w)...20 Ventilation...20 Mode Cooling...20 Recirculation Control...20 Frost Control...21 System Service...21 Maintenance...21 Monthly Maintenance...21 Annual Maintenance...21 Gas Module and Burner Maintenance...22 Appendix A: ERV1100w Overall Dimensions...24 Appendix B: ERV1100w Components...25 Appendix C: ERV1100w Rough-in (Ducting Only)...26 Appendix D: Remote Occupant Interface...27 Appendix E: Gas Burner Wiring Diagram...28 Appendix F: Electrical Data...29 Appendix G: Gas Flow Rate...30 Appendix H: Equipment in a Confined Space...31 Appendix I: Venting Options...32 Appendix J: Air Pipe Clearances and Vent Termination...33 Appendix K: DDC Keypad Reference Guide...34 Appendix L: ECM Motor cfm Adjustment Procedure...35 Venmar CES Inc 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. Manufacturer reserves the right to discontinue or change specifications or designs without notice or obligation. vces-vuv-iom-3 ERV1100w with Gas Heat 2

3 Nomenclature ERV1100w Nomenclature (1,100 cfm nominal) FROST CONTROL D Recirc defrost 1 E Exhaust only 2 V VSD frost prevention 3 N Non-defrost 2. VOLTAGE/SPEED A 120/1/60 - two-speed 4 B /1/60 - two-speed 5 C /1/60 - two-speed 5 D 208/3/60 - two-speed 6 E 230/3/60 - two-speed 6 F 460/3/60 - two-speed 6 3. HEATING E Electric heat H Hot water M High efficiency gas, modulating 4/7 T High efficiency gas, two-stage 4/7 P Proportional electric heat 8 R Hot gas reheat, on/off 9/10 S Hot gas reheat, modulating 9/10 X No heat 4. HEATING CAPACITY A No heat Electric Options B 2.5 kw (one-stage) 7 C 5.0 kw (one-stage) 11 D 5.0 kw (two-stage) 7 P 7.5 kw (one-stage) 12 E 7.5 kw (two-stage) 7 Q 10 kw (one-stage) 12 F 10 kw (two-stage) 7 R 12.5 kw (one-stage) 12 Hot Water Options I 50 to 70 MBH Hot Gas Reheat Options M 30 to 40 MBH 9 Gas Options J 40 MBH 7 K 60 MBH 7 5. GAS TYPE G Natural gas L Propane gas (CAN) P Propane gas (US) X Not applicable 6. COOLING C Chilled water 6/13 E Chilled water with condensate pump 6/13 Split System D Dx coil only 14 F Dx coil with condensate pump 14 Integrated System H Copper, WSHP 6 K Copper with condensate pump, WSHP 6 N Cupro-nickel, WSHP 6 P Cupro-nickel with condensate pump, WSHP 6 V Condensate pump only, for gas heat X No Cooling Notes: 1 When ordering recirc defrost, you must order an exhaust air damper. 2 An outside air damper must be selected. 3 Not available with two-stage compressors. 4 Not available with WSHP (water source heat pump) or electric heat options. 5 Requires a neutral wire with L1 and L2. 6 Not available with gas heating options. 7 Not available with three-phase voltage. 8 First stage is proportional and second stage (if applied) is fixed. 9 Only available with WSHP (water source heat pump) options. 10 Not available with controls option D Stand alone DDC controls. 11 Not available with 460/3/ Not available with single-phase voltage: 208/120/1 and 230/120/ FREE COOLING F Free cooling 21 X No free cooling 16. VALVES A Basic valve kit 9/19 B Motorized on/off 9/19 C Motorized on/off, automatic flow rate control 9/19 D On/off zone, automatic flow rate control 9/19 E Automatic flow rate control 9/19 F No valves, flexible hose kit only 9 X Not applicable COOLING CAPACITY A 2 ton B 2.5 ton C 3 ton D 3.5 ton 14 H 2.5 ton, two-stage 18 J 3 ton, two-stage 7/18 K 3.5 ton, two-stage 18 X Not applicable 14. REFRIGERANT B R410a X Not applicable 13. ENERGY RECOVERY 1 Aluminum wheel, no purge 12. EXTERNAL DISCONNECT N Non-fused disconnect switch 17 X No disconnect switch 11. RETURN AIR DAMPER 1 Motorized 2 Spring return 10. EXHAUST AIR DAMPER 1 Insulated motorized 2 Insulated spring return 3 No damper OUTSIDE AIR DAMPER 1 Insulated motorized 2 Insulated spring return 3 Insulated modulating spring return 4 No damper SUPPLY DISCHARGE T Top plenum, no grille 15 G Top plenum, c/w grille 15 D Top plenum, c/w double deflection grille S Silencer plenum, c/w grille 15 X No top plenum 7. CONTROLS D Stand alone DDC controls R Stand alone DDC controls with remote occupant interface X No controls - field provided low voltage sequencing required 13 Chilled water coil available with 3 ton capacities only. 14 Dx A coils available with 2, 2.5 and 3 ton 13 SEER. Not available for 3.5 ton option. 15 Not available with gas and does not allow top access for electrical or pipe routing. 16 Non-defrost only. 17 Non-fused disconnect switch is field installed (remote mounted). 18 Available with R410a WSHP (water source heat pump). 19 Option includes: ball valve, blowdown valve, strainer and p/t port. 20 Not available with WSHP (water source heat pump). 21 Supply and exhaust airflows will be unbalanced. Free cooling is not available with gas heating or hot gas reheat. vces-vuv-iom-3 ERV1100w with Gas Heat 3

4 Safety Considerations Warning, Caution and Important notes appear throughout this manual in specific and appropriate locations to alert Installing Contractors and 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. Identifies an instruction which, if not followed, might cause serious personal injuries including possibility of death. Caution Identifies an instruction which, if not followed, might severely damage the unit, its components, the assembly or final installation. Important Indicates supplementary information needed to fully complete an instruction or installation. Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual for assistance. For additional information, consult a qualified installer, service agency or the gas supplier. These instructions are intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require licensed installation or service personnel for this type of equipment. Read all instructions carefully before starting the installation. Do not destroy. Please read carefully and keep in a safe place for future reference. For your Safety What to do if you smell gas: Do not try to light any appliance. Do not touch any electrical switch. Do not use any phone in your building. Call your gas supplier immediately from a phone located outside the building. Follow the supplier s instructions. If you cannot reach your gas supplier, call the fire department. Extinguish any open flame. 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. Disconnect the main power switches to the unit before performing service or maintenance procedures. Electric shock can cause personal injury or death. Specifications The ERV1100w is a successful solution from Venmar CES to ventilation and indoor air quality problems. It is a commercial energy recovery ventilator with gas heat and/or Dx cooling. Designed as an appliance, it is ideally suited as a complete classroom ventilator. With an upright configuration and small footprint, it requires a minimum amount of space for installation. An optional top supply plenum allows for flexibility to suit various installations. The cabinet is well insulated and tightly sealed to provide quiet operation. Case Heavy gauge pre-finished steel, smooth texture, bone white finish Heavy gauge framework and shelving Dimensions 75.5 [1,918 mm] height without top supply plenum 41.0 [1,041 mm] width 30.5 [775 mm] depth Top supply plenum 16 [406 mm] or 25 [635 mm] height (optional) Airflow Supply Four-speed motor with two-speed operation ¾ hp 120 VAC 60 Hz Contact Manufacturer for airflow selection charts Exhaust Three-speed blower with single-speed operation ¼ hp 120 VAC 60 Hz Energy Recovery Module Aluminum enthalpy wheel Filtration All filters are 2 [51 mm] MEF disposable. Supply and exhaust filters are 12 x 24 [305 x 610 mm] vces-vuv-iom-3 ERV1100w with Gas Heat 4

5 Return filter is 16 x 15 [406 x 381 mm] Gas Heat Gas burner is available in two-stage or modulating operation. Natural gas is standard; LP conversion kits are available. Table 1: High Fire/Single-stage Operation Input 40,000 Btu/h 60,000 Btu/h Output 37,000 Btu/h 55,000 Btu/h Temperature rise range 35 F 65 F 45 F 75 F Table 2: Low Fire/Minimum Modulating Position Input 20,000 Btu/h 30,000 Btu/h All models are 120V, 60 Hz, single-phase. Gas connections are ½ [13 mm] NPT. Ratings to 2,000 feet [610 m]. Over 2,000 feet [610 m], reduce 4% for each 1,000 feet [305 m] above sea level. Category IV flue gas venting. Installation Requirements and Codes This unit must be installed in accordance with these instructions, all applicable local building codes, current revision of the National Fuel Gas Code (ANSI-Z223.1) and in Canada with the CAN/CGA-B149 installation code. The current revision of the National Fuel Gas Code is available from: American National Standards Institute, Inc Broadway New York, New York Additional helpful publications are: NFPA-90A Installation of Air Conditioning and Ventilating Systems NFPA-90B Installation of Warm Air Heating and Air Conditioning Systems These publications are available from: National Fire Protection Association, Inc. Batterymarch Park Quincy, Massachusetts Rough In Do not place combustible materials, including gasoline and any other flammable vapors and liquids, in the vicinity of the gas burner. Avoid operating the gas burner when windows and doors are open. Be sure that the thermostat is properly installed and is not affected by drafts or heat. The ERV1100w must be installed on a level base located as close to the vent (or chimney) as possible. Refer to Appendix A for rough in dimensions and clearances. Zero clearance is required between the bottom of the unit and any combustible material. See Table 3 for all other installation clearances. Do not block return air opening on the unit. Table 3: Minimum Clearances to Combustible Material Unit Minimum Clearances Input (Btuh) Side Vent Back Top Front 40, [25 mm] 1 [25 mm]* 60, [25 mm] 1 [25 mm]* * 24 [610 mm] is the minimum clearance for servicing. 36 [914 mm] is the recommended clearance for servicing. Unit Installed without Top Plenum The supply air ducting must be connected to the supply collar. Zero clearance is required between the supply duct and any combustible material. Air ducts must be installed in accordance with the Standard for the Installation of Air Conditioning and Ventilating Systems (NFPA-90A) or the Standard for the Installation of Warm Air Heating and Air Conditioning Systems (NFPA-90B). Drainage Combustion Air and Cooling Coil All units require a drain connection for the condensate from the condensing appliance. All units have a condensate line from the collector box on the gas module to the bottom of the unit. vces-vuv-iom-3 ERV1100w with Gas Heat 5

6 Units equipped with air conditioning have a condensate line connected at the top of the unit which must be fitted through the bottom of the case. A length of PVC hose is supplied within the case to make the drain connection when this component is purchased as an option. A water trap must be provided in the drain line to prevent back flow of sewer gases. This may be achieved by looping the drain line. The drain must be installed in an area in which it will not freeze. Both drain lines must be routed out of the unit. The condensate should drain from the plastic collector box as droplets or a small stream. If you notice the gas heat has operated for more than five minutes without draining or the red status light on the gas module control board is pulsing a two-blink code follow the steps below. 1. Remove the collector box soft tube and ensure the exit from the collector box is clear of any debris or obstructions. 2. Replace this tube and ensure the fit to the header spout is air-tight. Air will be drawn into the header if this connection is not tight. 3. Check other tube connections along the drain system. Ensure that all are air-tight. Important Industry research studies indicate that when condensate is routed to an active drain, detergents, etc., buffer its acidity. If the drain is not actively used or if codes require, obtain a neutralizer kit (usually contains limestone). Proper drains and connections to the condensate tubing are required as Venmar CES cannot be held responsible for water leakage which occurs due to loose hose connections or improperly sealed drain line pipes. See Appendix C for more rough in information. Power Caution Ensure that the power disconnect switch is off before connecting power to the unit or working with high voltage lines. Electrical installation must be completed in accordance to local and national electrical codes. Refer to Appendix F for electrical data. A sealed strain relief clamp (supplied by the Installer) must be fitted into the case to accommodate a power line connection (see Appendix A for knock-out location). If a sealed clamp cannot be used, the hole must be sealed with silicone or an equivalent water/air-tight sealant. Power must be connected to the unit through a fused disconnect switch (factory supplied option, field installed). If the unit has a top supply plenum, a hole for the power must be field punched in the plenum to accommodate the main power in. Terminals for line connection are located in the control box within the ERV1100w and are labeled as shown in Table 4 and Table 5. Connections are illustrated in Appendix D. Single Phase Table 4: Line Connection to 120 VAC, Single-phase, 60 Hz L1 Hot N Neutral GND Ground Table 5: Line Connection to 208 or 230 VAC, Singlephase, 60 Hz L1 Hot L2 Hot N Neutral GND Ground vces-vuv-iom-3 ERV1100w with Gas Heat 6

7 Controls The ERV1100w contains a stand alone controls package consisting of either a Direct Digital Controller (DDC) system or an optional no controls package for field installation and controls. The DDC system allows the ERV1100w to operate in either a stand alone capacity or in conjunction with numerous units via a field provided networking system. Stand Alone Controls (DDC) The mainframe for the stand alone DDC system is the programmable DSC-T305 controller/keypad. The DSC-T305 functions as a digital controller, LCD display for visual reference and as a 16-button keypad for user access to change operation parameters or to complete unit diagnostics. This controller is located within the ERV1100w and therefore can only be accessed by opening the front door of the unit. Heating icon Cooling icon Status message Current temperature Occupancy icon Figure 1: DSC-T305 controller display Supply fan level Time of day The DDC controller/keypad also may interface to expander modules (within the control box) to expand the input and output (IO) capabilities of the entire control system. Expander modules are deemed necessary based upon the requirements of the controls sequence. Important For complete unit set-up/configuration of the DDC controller system and outline of the troubleshooting guide, refer to the basic guide in Appendix K and the Sequence of Operation section for the DDC keypad operation. This guide is also placed within the unit for a more accurate description of the programmed parameters. The default four-digit Pin password for access to the DDC menus is Remote Occupant Interface (BacStat II) To provide remote monitoring and access of certain temperature setpoints and occupancy override features, a remote occupant interface option is available. This interface is referred to as the BacStat II and is connected to the DDC (DSC-T305) controller via the terminal strip within the unit. Without the remote occupant interface option, a 10K thermistor is connected to the terminal strip to provide the controller with the current room temperature. Refer to the Electrical Wiring section for the wiring description of both the remote occupant interface and room sensor. Refer to the Sequence of Operation section for general operation of the remote occupant interface (BacStat II) keypad. The remote occupant interface will allow a room occupant to adjust the room setpoint temperature and manually place the unit into occupancy override mode. By pressing the On button, this mode can be obtained for durations of 60, 120 or 180 minutes. Pressing the On button a fourth time will exit the occupancy override mode. No Controls Field Provided Low Voltage (Sequencing Required) A no controls package could be supplied to enable the end user to field supply and install a custom control system. In this application, the unit would contain the factory wiring and installation of basic electrical components such as damper relays, fan relays, electric heat contactors, low voltage transformer and standard terminals and connectors. Installation and operation of field supplied controls must provide the correct designed operation criteria of the unit. Incorrect unit operation could void the warranty of certain unit components and/or result in complete unit failure. vces-vuv-iom-3 ERV1100w with Gas Heat 7

8 Balancing Once installed, the ERV1100w must operate with balanced ventilation. Balanced ventilation is achieved by obtaining equal rates of outdoor and exhaust airflow. Airflow may be adjusted by balancing dampers (supplied by Installer) within the ductwork. Outdoor air volumes can be adjusted by changing the maximum open position on the opposed blade outdoor air damper. Systems operating with unbalanced airflow will not have effective energy recovery. Performance of the energy recovery module will be reduced and freezing may occur with cold outside air temperatures, resulting in blockage of the energy recovery module. Supply airflow can be adjusted on both low and high speed using the ECM motor cfm adjustment procedure in Appendix L. Ventilation/Recirculation Setting The ERV1100w fan speeds have been factory set to deliver a specified amount of outside and recirculation air. Maximum open positions of OA and RA may be set to adjust airflow. The ERV1100w must always be balanced on site. Products of combustion must not be allowed to enter the return air ductwork or the circulating air supply. Failure to prevent products of combustion from being circulated into the occupied space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death. All return ductwork must be adequately sealed, all joints must be taped and the ductwork and plenum must be secured to the unit with sheet metal screws. The floor or platform on which the unit is mounted must provide sound physical support of the unit with no gaps, cracks or sagging between the unit and the floor or platform. Circulating air ductwork must not be connected to any other heat producing device. Venting and Combustion Air Requirements The ERV1100w may be installed with outdoor combustion air piped directly to the appliance or without such special piping. Codes refer to the former as direct vent or two-pipe installation. Installation with air taken from around the appliance is sometimes referred to as onepipe installation (ex); only the vent (exhaust) pipe is provided. An important consideration in selecting one or two-pipe installation is the quality of the combustion air. Indoor air is sometimes contaminated with various chemicals which can cause severe corrosion in the appliance combustion system. Some common sources of these chemicals are detergents, bleaches, aerosol sprays, cements, glues and cleaning solvents. Unless indoor air is known to be free of these materials, two-pipe installation is recommended. Provisions must be made for adequate supply of air for combustion and ventilation. For United States installation, the adequacy of air provisions can be determined vces-vuv-iom-3 ERV1100w with Gas Heat by consulting the current version of the National Fuel Gas Code (ANSI Z223.1/NFPA-54). For Canadian installations, requirements are specified in the National Standard of Canada (CAN/CGA B149.1 and.2). Consult local codes for special requirements. Important If the unit is operated without adequate air for combustion and ventilation, it may not perform properly. Appliance components may be strained by high temperature and could fail prematurely. Appliance installation using methods other than those described in the following sections must comply with the National Fuel Gas Code and all applicable local codes to provide sufficient combustion air for the unit. 8

9 Air Requirements for One-pipe Installation When air for combustion is to be taken from around the ERV1100w, an opening must be provided in the plenum for adequate combustion air supply, as defined in the previous section. A protective screen must also be installed over the combustion air intake opening. This screen is provided with the unit installation instructions and functions to prevent debris from entering the combustion system. It should be installed on the combustion air intake collar or inlet PVC. If the unit location is such that this opening might be unintentionally obstructed, a 3 [76 mm] PVC elbow should be installed on the collar and the screen placed inside the inlet of the elbow. See Figure 2. Figure 2: Protective screen for one-pipe installation Tight buildings (with weather stripping and caulk to reduce infiltration) may require special provisions for the introduction of outside air to ensure satisfactory combustion and venting, even though the unit is located in an unconfined space. Installation in an Unconfined Space An unconfined space is an area including all rooms not separated by doors with a volume greater than 50 cubic feet per 1,000 Btuh of the combined input rates of all appliances which draw combustion air from that space. For example, a space including a water heater rated at 45,000 Btuh and an appliance rated at 75,000 Btuh requires a volume of 6,000 cubic feet [50 x ( ) = 6,000] to be considered unconfined. If the space has an 8 foot [2.4 m] ceiling, the floor area of the space must be 750 square feet (6,000 / 8 = 750). In general, an appliance installed in an unconfined space will not require outside air for combustion. Installation in a Confined Space A confined space is one which does not meet the unconfined space volume requirements and typically involves installation in a small room. All such installations must have specific provisions for introduction of combustion and ventilation air. Codes require that two openings be provided for this one with the bottom edge within 12 [305 mm] of the floor and one with the top edge within 12 [305 mm] of the ceiling. The size and other criteria for these openings must be per the following sections. Combustion air openings must not be restricted in any manner. Gas appliances installed in a confined space which supply circulating air to areas outside of the space must draw return air from outside the space and must have return air ducts tightly sealed to the unit. Air from Inside Air for combustion and ventilation may be taken from inside the building through an interior wall if the building is not tight and if the total volume of the appliance space and the space from which air is drawn meets the volume requirements for an unconfined space. In such cases, the two openings in the wall must each have free area of at least one square inch [6.45 sq. cm] per 1,000 Btuh of total appliance input, but not less than 100 square inches [ sq. cm] of free area. See Appendix H, Figure H1. For example, if the combined input rate of all appliances is less than or equal to 100,000 Btuh, each opening must have a free area of at least 100 square inches [ sq. cm]. If the combined input rate of all appliances is 120,000 Btuh, each opening must have a free area of at least 120 square inches [ sq. cm]. Air Directly Through an Exterior Wall If combustion air is provided directly through an exterior wall, the two openings must each have free area of at least one square inch [6.45 sq. cm] per 4,000 Btuh of total appliance input. See Appendix H, Figure H2. Outdoor Air Through Vertical Openings or Ducts If combustion air is provided through vertical ducts or openings to attics or crawl spaces, the two openings must each have free area of at least one square inch [6.45 sq. cm] per 4,000 Btuh of total appliance input. Ducts must have cross sectional areas at least as large as the free area of their respective openings to the appliance space. Attics or crawl spaces must communicate freely with the outdoors if they are the source of air for combustion and ventilation. See Appendix H, Figure H3 and Figure H4. Outdoor Air Through Horizontal Openings or Ducts If combustion air is taken from the outdoors through horizontal ducts, the openings must each have free area of at least one square inch [6.45 sq. cm] per 2,000 Btuh of total appliance input. Ducts must have a cross sectional area at least as large as the free area of their respective openings to the unit space. See Appendix H, Figure H5. Caution Do not supply combustion air from an attic space that is equipped with power ventilation or any other device that may produce a negative pressure. vces-vuv-iom-3 ERV1100w with Gas Heat 9

10 Venting Requirements For one-pipe installations, install vent piping to provide air for combustion and ventilation. For installations in the United States, the adequacy of air provisions can be determined by consulting the current version of the National Fuel Gas Code (ANSI Z223.1/NFPA-54). For Canadian installations, requirements are specified in the National Standard of Canada (CAN/CGA B149.1 and.2). Consult local codes for special requirements. The capacities in Table 7 apply to the total of vent and combustion air piping for either type of installation. The ERV1100w utilizes a condensing unit which is classified as a Category IV gas-fired appliance and requires special venting materials and installation procedures. Category IV appliances operate with positive vent pressure and therefore require vent systems which are thoroughly sealed. They also produce combustion condensate, which is slightly acidic and can cause severe corrosion of ordinary venting materials. Gas appliance operation can be adversely affected by restrictive vent and combustion air piping. Therefore, vent and combustion air piping lengths must conform completely to the requirements of Table 7. The gas appliance must be vented to the outdoors. This appliance must not be vented in common with any other appliance, even if that appliance is of the condensing type. Common venting can result in severe corrosion of other appliances or their venting and can allow combustion gases to escape through such appliances or vents. Do not vent the appliance to a building chase. Vent Pipe Material Vent and combustion air pipe and fittings must be one of the following materials and must conform to the indicated ANSI/ASTM standards: Table 6: Vent Pipe Material ANSI/ASTM Standards Material Schedule 40 PVC PVC-DWV SDR-21 and SDR-26 ABS-DWV Schedule 40 ABS Foam/cellular core PVC In Canada, all plastic pipe must be certified to ULC S636. Cement and primer must conform to ASTM Standard D2564 for PVC and Standard D2235 for ABS. When joining PVC piping to ABS, use PVC solvent cement. (See procedure specified in ASTM Standard D3138). Vent Pipe Length and Diameter In order for the unit to operate properly, the combustion air and vent piping must not be excessively restrictive. To ensure this use Table 7, which indicates the maximum allowable piping length for an appliance of specified input vces-vuv-iom-3 ERV1100w with Gas Heat Standard D1785 D2665 D2241 D2661 F628 F891 rate, when installed with piping of selected diameter and number of elbows. This table applies to the length and number of elbows for each pipe. To use the table, the appliance input rate, the center line length and the number of elbows on each pipe must be known. Choose the diameter for which the tabulated length is equal to or greater than required. Proper use of the table is illustrated by the following example: Example A 60,000 Btuh appliance is to be installed in a one-pipe system with 40 feet [12.2 m] of vent piping. There are four elbows, including those exterior to the building. Solution Consulting Table 7, in the single pipe length column for a 60,000 Btuh appliance, the maximum allowable length of 2 [51 mm] is 60 feet [18.3 m] with one elbow. Select 2½ or 3 [64 or 76 mm] pipe. For three additional elbows, deduct 2.5 feet [762 mm] for each elbow, or 7.5 feet [2.3 m] for a maximum installed vent length of 52.5 feet [16.0 m]. Condensing appliance combustion products have very little buoyancy, so Table 7 is to be used without consideration of any vertical rise in the piping. Important Always use the same or larger size piping for combustion air as is used for the exhaust vent. Vent Pipe Installation Pipe Routing and Support Route piping as directly as possible between the appliance and the outdoors and remember that routing affects pipe size requirements per the preceding section. If a two-pipe system is used, locate the combustion air intake and the vent exhaust in the same atmospheric pressure zone (ex) both must exit the building through the same portion of exterior wall or roof. Vent piping must be sloped upwards not less than ¼ per foot [6 mm per 305 mm] in the direction from the appliance to the terminal to ensure that any condensate flows back to the appliance (where it can be disposed of through the condensate disposal system). The quality of outdoor air must also be considered. Be sure that the combustion air intake is not located near a source of solvent fumes or other chemicals which can cause corrosion of the appliance combustion system. Appendix I shows typical horizontal and vertical venting configurations. Caution Combustion air must not be drawn from a corrosive atmosphere. 10

11 Table 7: Capacity Table Application Single Pipe Length (Ft) with One Long Radius Elbow Direct Vent, Dual Pipe Length (Ft) with One Long Radius Elbow on Each Pipe PVC, CPVC Inlet/ Inlet/ Inlet/ Outlet Outlet or ABS SCH. Outlet Outlet Outlet 40 Pipe Size* ,000 Btu/h input ,000 Btu/h input Subtract 2.5 feet [762 mm] for each additional 2 [51 mm] elbow and 3.5 feet [1.1 m] for each additional 3 [76 mm] elbow 2. Two 45 elbows are equivalent to one 90 elbow. 3. One short radius elbow is equivalent to two long radius elbows. 4. Do not include termination elbows in calculation of vent length. 5. This table applies to elevations from sea level to 2,000 ft [610 m]. For higher elevations, consult local codes for special requirements. 6. Only the above pipe materials are approved for use with G6 Condensing Appliances. 7. Single pipe installations must provide adequate combustion air in accordance with the National Fuel Gas Code (ANSI Z223.1/NFPA-54) or, for Canadian installations, CAN/CGA B and * For Canadian installations, all combustion air and vent pipes must be CSA or ULC certified schedule-40 PVC, PVC-DWV or ABSDWV pipe and cement. In Canada, all plastic pipe must be certified to ULC S636. Figure 3 below illustrates vent and combustion air pipe sizes exiting the appliance. Transition to the correct pipe size must be done close to the appliance so that the full length of pipe is of proper size. Combustion air inlet pipe collar diameter 3 [76 mm] for coupling or reducer Furnace top Code takes precedence over these instructions. Specifically, all minimum distance requirements with respect to termination of the vent piping listed below (items 1 through 8). 9 Direct.vent.terminal. 50,000.Btuh.or.less 12.ft..min. Mechanical.draft vent.terminal 4.ft..min. 4.ft..min. 12.ft..min. Mechanical.draft vent.terminal 12.ft..min. 12.ft..min. 12.ft..min. Figure 4: Vent termination clearances Less. than.10.ft. 3.ft..min. Grade 9. =. 229.mm 3.ft. =. 914.mm 4.ft. =. 1.2.m 10.ft.=. 3.0.m 12.ft.=. 3.7.m Mechanical.draft vent.terminal Forced.air.inlet Direct.vent.terminal more.than.50,000.btuh The following list is a summary of vent terminal location requirements: 1. The termination must be 12 [305 mm] above snow level or grade level whichever is higher. See Figure 5 for alternate method to achieve 12 [305 mm] above snow level. Vent configuration to provide 12 [305 mm] minimum height above snow level 12 [305 mm] minimum 19 [483 mm] maximum 2 [51 mm] PVC exhaust vent all models Figure 3: Appliance pipe adaptations Outside wall Pipe coupling Support ½ [13 mm] Armaflex insulation or equivalent 12 [305 mm] above normally expected snow level If breakable connections are required in the combustion air inlet (if present) and exhaust vent piping, then straight neoprene couplings for 2 or 3 [51 or 76 mm] piping with hose clamps can be used. These couplings can be ordered through your local appliance distributor. This appliance has been certified for installation with zero clearance between vent piping and combustible surfaces. However, it is good practice to allow space for convenience in installation and service. Location of Outdoor Terminations Vent and combustion air intake terminations must be located to ensure proper appliance operation and to conform to applicable codes. Figure 4 below illustrates necessary distances from the vent termination to windows and building air intakes. In Canada, the Canadian Fuel Gas Figure 5: Alternate horizontal vent installation 2. The minimum distance for a direct vent (one-pipe installation) from any door, (openable) window, or gravity air inlet is 4 feet [1.2 m] below, 4 feet [1.2 m] horizontally or 1 foot [305 mm] above. 3. The minimum distance for a direct vent (two-pipe installation) from any door, (openable) window, or air gravity inlet is 1 foot [305 mm] below, 1 foot [305 mm] horizontally or 1 foot [305 mm] above. 4. For one-pipe installations, the recommended (not required) minimum distance from an inside corner formed by two exterior walls is 6 feet [1.8 m]. vces-vuv-iom-3 ERV1100w with Gas Heat 11

12 5. The vent termination for a one-pipe installation shall be a minimum of 3 feet [914 mm] above any forced air inlet within 10 feet [3.0 m]. 6. The vent termination shall be located at least 4 feet [1.2 m] horizontally from any electric meter, gas meter, regulator and any relief equipment. These distances apply only to U.S. installations. In Canada, the Canadian Fuel Gas Code takes precedence. 7. Avoid areas where condensate drainage may cause problems by dropping on planters, sidewalks, etc. Also ensure that exhaust gases will not impinge on windows or building surfaces, which may be compromised or damaged by condensation. Do not install the vent terminal such that exhaust is directed into window wells, stairwells, into alcoves or similar recessed areas, and do no terminate above any public walkways. 8. Select the point of wall penetration where the minimum ¼ per foot [6 mm per 305 mm] of slope up can be maintained. Caution For optimum performance, vent the appliance through a wall which experiences the least exposure to winter winds. Horizontal Venting Vent and combustion air intake terminations must be as shown in Appendix I, Figure I1. Ensure that the combustion air vent and the exhaust vent are configured as shown in Appendix I, Figure I1. Improper vent termination can cause recirculation of the flue gases, resulting in appliance vibration. In severe cases, the appliance will cycle due to the intermittent contact between the flame and the flame sensor. If you note oscillations occurring, check the vent configuration. Make sure that the exhaust vent does not have a 90 termination. For horizontal venting, one of the following kits is recommended: Table 8: Recommended Horizontal Venting Kits Kit 2 PVC 3 PVC Through-the-wall exterior vent mounting kit PN PN Neutralizer kit (all models) PN PN For Canadian installations please refer to the Canadian Installation Code (CAN/CGA-B149.1 or 2) and/or local codes. The kit consists of two face plates and an insulating gasket to seal the exterior surface. A hole sized closely to the pipe diameter must first be cut through the wall. A short length vces-vuv-iom-3 ERV1100w with Gas Heat of pipe is then cut such that it can penetrate the wall and be held in place by closely fitting standard couplings. The face plates are retained on both sides of the wall by the couplings and the gasket is retained against the wall by the outer face plate. Face plates must be fastened to the wall and the outside one must be flashed as appropriate to prevent entry of water. When the above kits are not used the following steps are required: 1. Check the hole size cut through the exterior wall. Ensure that the hole diameter is less than the diameter of the couplings to be used. 2. Extend the vent pipe through the wall approximately 1 [25 mm] and seal the area between the wall and pipe. 3. Apply couplings to the vent pipe on the interior and exterior sides of the wall to ensure the pipe cannot be pushed or pulled through the wall. 4. Ensure the combustion air inlet pipe (for a two-pipe installation) has a 90 termination elbow as shown in Appendix I, Figure I1 and Figure I2. Note that a combustion air intake must be provided with an elbow opening downward. The screen provided with the appliance must be installed in the elbow to prevent entry of debris or creatures. When the vent pipe must exit an exterior wall close to the grade or expected snow level, a riser should be provided as shown in Alternate Horizontal Vent Installation. Insulation is required to prevent freezing of this section of pipe. Vertical Venting Appendix I, Figure I2 shows the proper installation and clearances for vertical vent termination. The roof penetration must be properly flashed and waterproofed with a plumbing roof boot or equivalent flashing. Termination spacing requirements from the roof and from each other must be per Appendix I, Figure I2. Vent and combustion air piping may be installed in an existing chimney which is not in use provided that: 1. Both the exhaust vent and air intake run the length of the chimney. 2. The top of the chimney is sealed and weatherproofed. 3. The termination clearances shown in Appendix I, Figure I2 are maintained. 4. No other gas fired appliances are vented through the chimney. Vent Freezing Protection When the vent pipe is exposed to temperatures below freezing (ex. when it passes through unheated spaces, chimneys, etc.), the pipe must be insulated with ½ [13 mm] thick sponge rubber insulation, Armaflex-type insula- 12

13 tion or equivalent. Insulation pipe is important to avoid condensate icing. For extremely cold climates or for conditions of short appliance cycles (ex. setback thermostat conditions), the last 3 feet [914 mm] of vent pipe can be reduced one nominal pipe size provided that the total vent length is at least 15 feet [4.6 m] in length and the vent is sized in accordance with the venting requirements (Table 7) before this reduction is applied (ex. 3 to 2½ [76 to 64 mm] or 2 to 1½ [52 to 38 mm]). Smaller vent pipes are less susceptible to freezing, but must not be excessively restrictive. Concentric Vent Termination A concentric vent termination is approved for use with the ERV1100w (kit PN ). For proper installation of concentric vent termination, follow the instructions provided with the kit. Conversion Kits Conversion of this appliance to use LP/propane gas must be made by qualified service personnel, using only approved parts. High Altitude Application High altitude application with this appliance can be field performed by a simple adjustment of manifold pressure, and if necessary, changing the orifices. The changes required depend on the installation altitude and the heating value of the gas. The gas heating value based on sea level can be obtained from your local gas utility. The heating value of gas at high altitude is always lower than the sea level heating value. The heating values used in Table 9 and Table 10 are based on sea level values. Natural Gas High Altitude Conversion All factory shipped appliances are ready to operate between zero and 4,999 feet above sea level. For higher altitudes (between 5,000 and 10,000 feet above sea level), conversion can be achieved simply by adjusting the appliance manifold pressure as shown in Table 10. LP/Propane Gas Sea Level and High Altitude Conversion Conversion of this appliance to utilize LP/propane gas must be made by qualified service personnel, using factory authorized or approved parts. Conversion to LP/propane gas can be accomplished by first replacing the natural gas orifices with the appropriate LP/propane orifices shown in Table 11. Important For installations between zero and 5,000 feet [1,524 m] above sea level, a #54 or #55 drill size orifice should be used depending upon the rated firing rate of the unit (see Table 11). However, for installations more than 5,000 feet [1,524 m] above sea level, a #55 or #56 drill size orifice should be used. After changing the orifices, use Table 10 to determine the appropriate manifold pressure for your installation. Conversion to LP/propane, sea level, and high altitude is detailed in the installation instructions provided with the conversion kit. Approved conversion kits are listed below. United States: LP/Propane Gas Sea Level and High Altitude Conversion Kit (PN ) Canada: LP/Propane Gas Sea Level and High Altitude Conversion Kit (PN ) Gas Supply and Piping This appliance was equipped at the factory for use with natural gas only. A special kit, supplied by the manufacturer, is required to convert the appliance to operate on LP/propane gas. Failure to use the proper conversion kit can cause fire, explosion, property damage, carbon monoxide poisoning, personal injury or death. General A typical gas service hookup is shown in Figure 6. When making the gas connection, provide clearance between the gas supply line and the entry hole in the gas burner casing to avoid unwanted noise and/or damage to the gas burner. vces-vuv-iom-3 ERV1100w with Gas Heat 13

14 All gas piping must be installed in compliance with local codes and utility regulations. Some local regulations require the installation of a manual main shut-off valve and ground joint union external to the gas burner. The shut-off valve should be readily accessible for service and/ or emergency use. Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut-off. In the absence of local codes, the gas line installation must comply with the latest edition of the National Fuel Gas Code (ANSI Z223.1) or (CAN/CGA B149.1 or.2) Installation Codes. Note: Some utilities require the shut-off valve to be 4 to 5 feet [1.2 to 1.5 m] above floor AutomaticgGas valve (with manual shut-off) Shut-off valve with 1/8 [3 mm] NPT plugged tap Table 9: Manifold Pressure (in. w.c.) for Natural Gas at Various Altitudes Natural Gas Sea Level Heating Value of 800 to 899 Btu/cu.ft. Natural Gas Sea Level Heating Value (Btu/cu.ft) 0 to 1,999 Elevation (Feet Above Sea Level) 2,000 to 4,999 5,000 to 5,999 6,000 to 7,999 8,000 to 10, to w.c. 3.5 w.c. 3.5 w.c. 3.5 w.c. 3.0 w.c. 900 to w.c. 3.5 w.c. 3.5 w.c. 3.2 w.c. 2.8 w.c. 1,000 to 1, w.c. 3.5 w.c. 3.0 w.c. 2.8 w.c. 2.5 w.c. Table 10: Manifold Pressure (in. w.c.) for LP/Propane Gas at Various Altitudes Natural Gas Sea Level Heating Value of 800 to 899 Btu/cu.ft. LP Gas Heating Value (Btu/hr) 0 to 1,999 Elevation (Feet Above Sea Level) 2,000 to 4,999 5,000 to 5,999 6,000 to 7,999 8,000 to 10,000 2, w.c. 8.5 w.c w.c. 9.0 w.c. 8.5 w.c. Table 11: Natural Gas and LP Gas Orifice Sizes Elevation (Above Sea Level) 0 to 4,999 feet 5,000 to 10,000 feet Burner assembly Ground joint union Dripleg Orifice Drill Size Orifice Drill Size Gas Appliance Rating Plate Input (Btu/hr) Natural Natural LP LP Gas Gas 45, , Manifold Figure 6: Typical gas service connection An 1/8 [3 mm] NPT tap must be installed in the gas line to the unit for use when measuring the gas supply pressure. The tap should be readily accessible for service use. A drip leg should be installed in the vertical pipe run to the unit. Table 12 lists gas flow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line. Important 1. Gas piping must not be run in or through air ducts, chimneys, gas vents, elevator shafts, etc. 2. Compounds used on threaded joints of gas piping must be resistant to the actions of liquefied petroleum gases. 3. The main manual gas valve and main power disconnect to the gas burner must be properly labeled by the Installer in case emergency shut down is required. Table 12: Gas Pipe Capacity Capacity of Black Iron Gas Pipe (cu.ft./hr) for Natural Gas (Specific Gravity 0.60) Nominal Black Length of Pipe Run (ft) Iron Pipe Diameter ½ ¾ ¼ 1, ½ 1,600 1, The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by the gas burner. To determine the cubic feet per hour of gas flow required by the gas burner, divide the input rate of the gas burner by the heating value of the gas: Cubic feet/hour required: Input to Gas Burner (Btu/hr) Heating Value of Gas (Btu/cu. ft.) Leak Check After the gas piping to the gas burner is complete, all connections must be tested for gas leaks. To check for leaks in gas piping systems, use only a soap and water solution or other approved method. Caution Do not use matches, lighters, candles or other sources of open flame to check for gas leaks. vces-vuv-iom-3 ERV1100w with Gas Heat 14

15 Important When pressure testing the gas supply lines at pressures greater than ½ psig [14 w.c.], the gas burner must be disconnected from the gas supply piping system to prevent damage to the gas control valve. If the test pressure is less than or equal to ½ psig [14 w.c.], the gas burner must be isolated from the gas supply line by closing the manual shutoff valve. Conversion Conversion of this gas burner to use LP/propane gas must be made by qualified service personnel, using only factory authorized or approved parts. This gas burner was equipped at the factory for use with natural gas only. A special kit, supplied by the Manufacturer, is required to convert the gas burner to operate on LP/propane gas. Failure to use the proper conversion kit can cause fire, explosion, property damage, carbon monoxide poisoning, personal injury or death. High Altitude Derate The input rating on the gas burner nameplate applies for elevations up to 2,000 feet [610 m] above sea level. For elevations above 2,000 feet [610 m], the input must be derated by 4% per 1,000 feet [305 m]. For example, at an elevation of 5,000 feet [1,524 m], the gas burner should be derated by 20%. This is necessary to compensate for changes in gas flow rate and burner operation. Table 11 shows the approximate orifice size for reducing the input rate of an appliance installed at elevations of 2,000 feet [610 m] and higher. Example 1 Elevation: 3,890 feet [1,186 m] Type of gas: Natural Gas Burner Capacity: 72,000 Btu/h Orifice as shipped: #43 Drill See Table 11 for natural gas, find the Gas Appliance Rating Plate Input Btuh and follow across the table for the elevation 2,000 to 4,000 column. From the table, choose a #44 orifice. Install a #44 orifice in every burner and check the firing rate per the Verifying and Adjusting Firing Rate section. The firing rate in this example must not exceed 81,000 Btuh. Important The density of air decreases with increasing elevation above sea level. This reduces the quantity of combustion air drawn into the gas burner under normal operation and requires the unit be derated by using smaller gas orifices. The gas heating value must be for the altitude at which the gas burner is applied. At 5,000 feet [1,524 m] for example, the heating value of the gas is about 84% of the sea level value. A Coil Mounting Position the cooling coil over the opening in the top of the unit. The connection lines must face to the left as shown in Figure 7. Ensure not to damage the foil faced insulation. Lower the top plenum over the coil and ensure that the coil fits closely to the separator panel walls and is square with the main cabinet. Figure 7: Position cooling coil over unit top opening Figure 8: Lower top plenum vces-vuv-iom-3 ERV1100w with Gas Heat 15

16 Attach the coil to the top of the cabinet with brackets provided. Make solder connections as required. Coil Condensate drain hose Figure 10: A coil top view Figure 9: Attach coil to top of cabinet Make condensate drain line connections as required using plastic hose and fittings provided. The cooling coil condensate drain line can be tee d into the gas module or run separately to the building connection. Electrical Wiring To avoid electric shock, personal injury or death, turn off the electric power at the disconnect or the main service panel before making any electrical connections. General Electrical connections must be made in accordance with all applicable local codes and ordinances and with the current revision of the National Electric Code (ANSI/NFPA 70). For Canadian installations the electrical connections and grounding shall be done in accordance with the current Canadian Electrical Code (CSA C22.1, Part 1 and/or local codes). If any of the original wire (as supplied with the gas burner) must be replaced, replace it with wire having a temperature rating of at least 221 F [105 C]. Refer to the gas burner nameplate and Specifications section for electrical requirements. The gas burner cabinet must have an uninterrupted, unbroken ground to minimize injury should an electrical fault condition occur. The controls used in this unit require an earth ground in order to operate properly. Acceptable methods for grounding are electrical wire or conduit approved for electrical ground service. Do not use gas piping as an electrical ground. vces-vuv-iom-3 ERV1100w with Gas Heat All electrical wiring must be installed where it is protected from water. Important Proper line voltage polarity must be maintained in order for the control system to operate correctly. Verify that the incoming neutral line is connected to the white wire. The gas burner will not operate unless the polarity and ground are properly connected. Caution Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. BacStat II (Option) Wiring The BacStat II provides remote monitoring and access of certain temperature setpoints and occupancy override features. The BacStat II must be connected to the terminal strip using a four-conductor shielded cable and be wired as follows: Table 13: BacStat II Connections to Terminal Strip BacStat II Sensor Terminal Strip 24 VAC Wired to PWR 24V GND Wired to COM + Wired to NET + Wired to NET 16

17 Room Temperature Sensor Wiring Without the BacStat II option, the room temperature is provided to the DDC controller via the wiring of a 10K thermistor. This thermistor must be connected to the terminal strip using a two-conductor shield cable, wiring one wire to the terminal 10K thermistor 1 and the other to the terminal 10K thermistor 2 (see Appendix D). General Wiring Auxiliary heating, auxiliary cooling and 24 VAC connections are available for field wiring on the unit terminal strip. Each of the auxiliary terminals provide 24 VAC during the applicable stage (ex. 24 VAC on auxiliary cooling terminal during cooling modes) while the 24 VAC terminals provide approximately 30 VA of power output. System Operation Start-up and Adjustments Should overheating occur or the gas supply fail to shut off, shut off the manual gas valve to the appliance before shutting off the electrical supply. Important Read the safety information on the following pages before operating. Do not use this unit if any part has been under water. Call a qualified service technician immediately to inspect the gas module and to replace any part of the control system and any gas control which has been under water. These appliances are equipped with rollout limit switch(es), a vent safety switch and a pressure switch. The pressure switch verifies that the flame is receiving combustion air. If the flame is not drawn into the heat exchanger tube, the roll out limit switch or flame sensor will shut the appliance down. The vent safety switch shuts the appliance down if the vent becomes blocked or restricted. Appliance Fails to Operate If the appliance does not operate, check the following: 1. Is the DDC keypad operating properly? 2. Are the blower door(s) in place? 3. Is the appliance disconnect closed? 4. Has the circuit breaker tripped (or fuse blown)? 5. Is the gas turned on? 6. Is the filter dirty or plugged? If the combustion and circulating air blowers are operating, and items 1 through 6 have been checked without identifying the cause of the problem, press the red reset buttons on the vent safety and the rollout limit switches. Important If the appliance operates after depressing the reset button on the vent limit or rollout limit, it is an indication of a potentially serious problem in the installation. Contact a qualified serviceman to identify and repair the problem. General Prior to start-up, verify that: 1. The line voltage power leads are securely connected, that the polarity of the connections are correct and that the gas burner is properly grounded. 2. The BacStat II or 10K thermistor are securely connected to the correct terminals on the unit terminal strip. 3. The gas line service pressure does not exceed 10.0 w.c. [0.36 psig] and is not less than 4.5 w.c. [0.16 psig] for natural gas. For LP gas, the line service pressure must not exceed 14.0 w.c. [0.51 psig] and must not be less than 11.0 w.c. [0.40 psig]. 4. The roll-out manual reset switch is closed. If necessary, press the red button to reset a switch. Do not install a jumper wire across a switch to defeat its function. If a switch re-opens on start-up, do not reset the switch without identifying and correcting the fault condition which caused the switch to trip. 5. The blower door is in place, closing the door switch in the line voltage circuit. 6. The gas line has been purged and all connections are leak-tight. Start-up Procedures for Gas Heat After all of the above checks have been made: 1. Adjust the temperature setting to initiate a heating call. 2. Close the disconnect(s) to provide line voltage to the gas burner. 3. Follow the procedures given on the operating instruction label attached to the gas burner. 4. Set the room setpoint above room temperature and verify the operating sequence (see the Sequence of Operation, Heating Mode section). 5. After the gas burner has run for approximately five minutes, set the room setpoint below room temperature and verify steps 9 through 11 of the Sequence of Operation, Heating Mode section. vces-vuv-iom-3 ERV1100w with Gas Heat 17

18 Verifying and Adjusting Firing Rate The firing rate must be verified for each installation to prevent over-firing the gas burner. Important The firing rate must not exceed the rate shown on the gas burner rating plate. At altitudes above 2,000 feet [610 m] it must not exceed that on the rating plate less 4% for each 1,000 feet [305 m]. Determine the firing rate with the following procedure: 1. Shut off all other gas fired appliances. 2. Start the gas burner and allow it to run for at least three minutes. 3. Measure the time (in seconds) required for the gas meter to complete one revolution. 4. Convert the time per revolution to cubic feet of gas per hour using Appendix G. 5. Multiply the gas flow rate in cubic feet per hour by the heating value of the gas in Btu per cubic foot to obtain the firing rate in Btu per hour. Example: Time for one revolution of a gas meter with a one cubic foot dial = 40 seconds. From Appendix G read 90 cubic feet per hour of gas. Heating value of the gas (obtained from gas supplier) = 1,040 Btu per cubic foot. Firing rate = 1,040 x 90 = 93,600 Btuh. 6. Relatively small adjustments to the firing rate can be made by adjusting the gas manifold pressure. 7. See the High Altitude Derate section for additional information of firing rate at elevations above 2,000 feet [610 m]. The gas valve regulator is set at a nominal value of 3.5 w.c. for use with natural gas. The manifold pressure must be set at 10.0 w.c. for use with Propane gas. To adjust the manifold pressure, remove the regulator cap and turn the adjusting screw clockwise to increase pressure or counter-clockwise to reduce pressure. Replace the regulator cap after adjustments are complete. Caution Do not re-drill the burner orifices. If the orifice size must be changed, use only new orifices. Verifying and Adjusting Temperature Rise Verify the temperature rise through the gas burner is within the range specified on the gas burner rating plate. Temperature rises outside the specified range could result in premature heat exchanger failure. Verifying Burner Operation To verify operation of the burners, make sure that the top door is in place and that there is power to the gas burner. Set the thermostat to a temperature above room temperature and observe the ignition sequence. The burner flame should carry over immediately between all burners. The flames should be blue, without yellow tips. Flames should extend from each burner without lifting off, curling or floating. After verifying satisfactory flame characteristics, set the thermostat to a temperature below room temperature and verify that the burner flame extinguishes completely. Verify Operation of the Supply Air Limit Switch To verify operation of the supply air limit switch, make sure that the blower door is in place and that there is power to the gas burner. Block the return airflow to the gas burner by installing a close-off plate in place of or upstream of the filter(s). Set the thermostat to a temperature above room temperature and verify that the sequence of operation is as described in these instructions. The limit switch should function to turn off the gas valve within approximately four minutes (the exact time depending on the efficiency of the close-off in blocking the return air to the gas burner). The circulating air and combustion blowers should continue to run when the limit switch opens. Remove the close-off immediately after the limit switch opens. If the gas burner operates for more than four minutes with no return air, set the thermostat to a temperature below room temperature, shut off the power to the gas burner and replace the limit switch. vces-vuv-iom-3 ERV1100w with Gas Heat 18

19 Sequence of Operation Heating Mode 1. On a call for heat, the DDC controller provides 24 VAC to the W terminal on the gas control board. 2. The control board checks for continuity on the 24 VAC limit control circuit (over temperature limit switch, flame rollout switches and blocked vent switch in series). If an open limit is detected, the control board will energize the inducer and the conditioned air blower. All other system functions will be inoperable until the limit circuit closes. While the limit is open, the red LED will pulse at a rate of one blink per unit time. 3. The gas burner control checks for continuity across the pressure switch (24 VAC). If the pressure switch is closed, the heat mode sequence will not continue. If it remains closed for 10 seconds the red LED will blink three times repetitively until the fault condition clears. 4. The inducer is energized. 5. The pressure switch will close. If the pressure switch does not close after 10 seconds, the fault LED will blink two times repetitively and the inducer will continue to run until the switch is closed. 6. The inducer will pre-purge for 30 seconds and then the ignitor will start its warm-up. After 30 seconds of ignitor warm-up, the gas valve (24 VAC) will open. The ignitor circuit stays energized for six seconds after the gas valve opens. 7. The gas burner control must prove flame via the flame sensor six seconds after the gas valve opens. If flame is sensed, all burners are on and the ignitor cools off. If no flame is sensed, the gas valve closes immediately and the inducer continues to run. A second trial for ignition (Step 6) begins if no flame is sensed on the fifth try for ignition, the gas burner control is locked and the red LED will blink four times repetitively. The thermostat must be opened for at least 10 seconds to reset the gas burner control after a lockout. Otherwise, the gas burner will attempt another ignition sequence in one hour. 8. The gas burner control energizes the circulating air blower on the heating speed 30 seconds after the gas valve circuit is energized. 9. When the room temperature has been satisfied, the gas valve is de-energized. 10. The inducer is de-energized after a 30 second postpurge. 11. The gas burner control keeps the circulating air blower energized for 120 seconds (factory set) or 60, 90 or 180 seconds (field adjustable). 12. Abnormal conditions: If a limit opens during operation, the inducer and circulating air blower continue to operate. The gas valve is de-energized immediately. The blowers continue to operate until the limit closes. When the limit closes, the inducer blower is de-energized immediately. The circulating air blower continues to operate for the specified delay (factory set at 120 seconds). Important The gas module will always start the heating sequence on high fire and drop back to low or modulate as required. Gas Burner Fails to Operate If the gas burner does not operate, check the following: 1. Is the DDC controller operating properly? 2. Are the blower compartment door(s) in place? 3. Is the gas burner disconnect closed? 4. Has the circuit breaker tripped or the control board fuse burned open? 5. Is the gas turned on? 6. Are any manual reset switches open? 7. Is the filter dirty or plugged? 8. Is the flame sensor coated? Remove and clean with an emery cloth. vces-vuv-iom-3 ERV1100w with Gas Heat 19

20 Sequence of Operation (ERV1100w) Many parameters on the DDC controller may be adjusted to alter the durations and setpoints of the sequence of operation of the ERV1100w. Refer to Appendix K and the Controls section for more specific details of each parameter. DDC Controller/Keypad (DSC-T305) Table 14: DDC Controller/Keypad (DSC-T305) Symbol Key Name Description Thermometer key Clock key Schedule key Occupancy key Parameter keys Increment keys Used to display the room setpoint. Used to display the time and date. Used to display On and Off times. Used to initiate manual occupancy. Used to cycle through parameters. Used to increase or decrease values. Remote Occupant Interface (BacStat II) Keypad Table 15: Remote Occupant Interface (BacStat II) Keypad Symbol Key Name Description Increment keys Used to increase or decrease values. Heating/Cooling Operation First Stage Heating 24 VAC on auxiliary heating terminal. Supply fan to low speed. Second Stage Heating 24 VAC on auxiliary heating terminal. Supply fan to low speed. First Stage Cooling (Free Cooling) 24 VAC on auxiliary cooling terminal. Supply fan to high speed. Wheel rotation is off. Second Stage Cooling (Air Conditioning) 24 VAC on auxiliary cooling terminal. Supply fan to high speed. Wheel rotation is on. Ventilation Ventilation time periods will be determined through the schedule programming of the DDC system. Using the DDC keypad, the operator is able to select the on and off times on a daily, weekly or monthly basis. Refer to Appendix K and the Sequence of Operation (ERV1100w) section for adjustment of the ventilation schedule. Mode Cooling First stage cooling with the ERV1100w puts the supply fan and exhaust fan to high speed and stops the energy recovery wheel. Second stage cooling is an option and calls for Dx cooling from a remote condensing unit. The supply fan runs on high speed and the energy recovery wheel rotates. Recirculation Control In ventilation mode, the ventilation damper is open and the supply air is a mixture with a percentage of return air. In recirculation mode, the ventilation damper is closed, 100% of the supply air is recirculated air from the return plenum. Units equipped with recirculation control are built with a damper mechanism controlling air flow through the intake duct. Ventilation mode is activated by the DDC controller schedule. vces-vuv-iom-3 ERV1100w with Gas Heat 20

21 Frost Control Units with frost control are equipped with recirculation control. The frost control program within the DDC controller determines the frost control strategy and operation. The DDC control program is activated by a thermistor which monitors the outside air temperature passing through the air intake. When in ventilation mode at temperatures below 5 F [ 15 C], the timer/controller activates frost control periodically to keep the enthalpy wheel free from frost. System Service Maintenance Disconnect the main power switch to the unit before performing service or maintenance procedures. Do not place combustible materials on or against the appliance cabinet. Do not store gasoline or any other flammable vapors and liquids in the vicinity of the appliance. Annually inspect the appliance, ductwork and vent system for signs of physical deterioration. Change or replace the air filters monthly during any period when the circulating blower is operating regularly. Always replace the doors on the appliance after servicing or cleaning/changing the filters. Do not operate the appliance without all doors and covers in place, except to check burner operation. Avoid operating the appliance when windows and doors are open. Be sure that the BacStat II is properly installed and is not being affected by drafts or heat from lamps or other appliances. Monthly Maintenance Air Filters The standard medium efficiency filters are disposable and should be replaced monthly or as required by operating conditions. When installing a new filter, the airflow arrow should point in the direction of the enthalpy wheel. To remove the supply filter, open the filter access door, reach behind the enthalpy wheel and pull out the filter. To remove the exhaust filter, remove the bottom door and slide the filter out from behind the door. Screens and Drains The vent terminal screens and gas burner condensate drain must be cleaned monthly. Never operate the gas burner without a filter in place. Dust and lint in the return air can build up on internal components, resulting in a loss of efficiency, equipment damage and possible fire. Annual Maintenance Interior of Unit The inside of the unit should be wiped clean annually with a soft cloth and mild cleaning solution. Enthalpy Wheel No cleaning of the enthalpy wheel is required. It is selfcleaning due to the opposing airflows. If the enthalpy wheel is cleaned, use low pressure air or a vacuum. Visually inspect the cassette brush seals and drive belt (Figure 11) for proper operation. Rotor Figure 11: Brush seal Brush.seal vces-vuv-iom-3 ERV1100w with Gas Heat 21

22 Disconnect the main power switch to the unit before performing service or maintenance procedures. Air Conditioning Coil Check the air conditioning coils for obstruction or buildup of dust. If the red buttons are released out, depress the red button to reset the switch. If this problem persists, call your local technician. Dampers Check dampers for obstruction and cleanliness. Fans Blower wheels and fan housings should be checked for dust build-up. If excessive dust build-up exists, it will be necessary to remove the blower assembly to clean the dust out through the fan mouth. To remove the supply blower, first remove the screw holding the blower in place. Disconnect the electrical wiring by removing the wire quick connects and sliding the blower out of the unit. To remove the exhaust blower, the enthalpy wheel must be removed. Unplug the electrical connector for the enthalpy wheel and slide it out of the unit. Disconnect the damper actuator and exhaust fan wiring by removing the wire quick connects. Remove the two bolts and slide the exhaust blower and actuator out. Gas Burner It is recommended that the gas burner be checked yearly. Products of combustion must not be allowed to enter the living space. Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death. Vent System Check the vent pipe to ensure that it is not corroded or blocked by debris. Any corroded section of vent pipe must be replaced and any obstruction or blockage must be removed prior to operating the gas burner. Important The venting pipe must only be installed in the venting chase in the top plenum. Do not run any portion of the vent system into or through any duct or plenum. The venting chase must be screwed to the top of the unit to seal it off from the plenum. Gas Module and Burner Maintenance Burner Maintenance Check the burner flames at the start of every heating season. Set the thermostat to a temperature setting above the room temperature. Remove the top door from the appliance and visually inspect the burner through the view hole to make sure that the flame is drawn into the center of the heat exchanger tube (see Figure 12). In a properly adjusted burner assembly, the flame bends down and to the right at the end of the heat exchanger tube. The end of the flame will be out of sight around the bend. The flame color should be blue, however some light yellow streaks may occur on the outer portions of the flame. Burner Flame Caution Some components in the burner vestibule are at high temperatures while the burners are operating. Use caution to avoid personal injury. Do not operate your gas appliance if you find any of the following conditions. Such conditions may allow toxic fumes to escape into your building: Obstructions or restrictions in the vent pipe and/or chimney. Holes or cracks in the vent pipe. Visible corrosion in the vent pipe. Horizontal vent pipes that do not slope upward. If any of the above conditions are found in the vent pipe, call a qualified service technician to install new vent pipe. Figure 12: Burner inspection Manifold vces-vuv-iom-3 ERV1100w with Gas Heat 22

23 Disconnect the main power switch to the unit before performing service or maintenance procedures. The gas burner should operate for many years without soot buildup in the flue passageways, however, the flue passageways, the vent system and the burners should be inspected and cleaned (if required) by a qualified serviceman annually to ensure continued safe operation. Particular attention must be given to identify deterioration from corrosion or other sources. Holes in the vent pipe or heat exchanger can cause products of combustion to enter the building. Replace the vent pipe or heat exchanger if leaks are found. Failure to prevent products of combustion from being circulated into the living space can create potentially dangerous conditions including carbon monoxide poisoning that could result in personal injury or death. Cleaning of Flue Passages If the flue passages must be cleaned due to soot buildup, follow the steps below. See Appendix B for component location and identification. 1. Shut off the gas supply to the gas burner either at the meter or at the manual valve in the gas supply piping. 2. Turn off all power to the gas burner and set the thermostat to the lowest temperature setting. 3. Remove the louvered door from the gas burner. 4. Turn the gas control lever to the Off position. 5. Disconnect the wires from the gas valve, ignitor, flame sensor, combustion air motor, flame rollout switch, blocked vent switch, over temperature limit switch and the pressure switch. 6. Remove the silicone rubber tube from the collector pan. 7. Remove the screws that hold the vent control assembly to the top panel. 8. Remove the nuts that hold the combustion air motor to the collector pan and remove the complete combustion air blower and combustion tube assembly. Be careful not to break the seals at each end of the combustion air tube. 9. Remove the screws that hold the collector pan in place and remove the collector pan from the gas burner. 10. Using wrenches, separate the ground joint union in the gas supply piping at the gas burner. 11. Remove the piping between the gas valve and the ground joint union, if necessary. 12. Remove the four screws holding the burner assembly in place and remove the burner assembly. Be extremely careful not to damage the ignitor while removing the burner assembly. 13. The gas burner heat exchanger tubes can now be cleaned by the use of a round wire brush attached to a length of high grade stainless steel cable, such as drain cleanout cable. Attach a variable speed reversible drill to the other end of the spring cable. Slowly rotate the cable with the drill and insert it into the top portion of the heat exchanger. While reversing the drill, work the cable in and out several times to obtain sufficient cleaning. Repeat this sequence for each heat exchanger tube. 14. When all heat exchanger tubes have been cleaned, any debris inside the tubes can be removed with the nozzle of a vacuum cleaner. 15. With a light, check the condition of the upper and lower sections of the heat exchanger tube. 16. Inspect the burners and clean them (if necessary) with a soft wire brush and/or the nozzle of a vacuum cleaner. Be extremely careful not to damage the ignitor while cleaning the burner. 17. Replace all the parts in reverse order from which they were removed. 18. Follow the lighting instructions found on the unit door to return the unit to operation. Verify proper operation after servicing. Cleaning of Burners If the burners must be cleaned, follow the steps below. See Appendix B for component location and identification. 1. Shut off the gas supply to the gas burner either at the meter or at a manual valve in the supply piping. 2. Turn off all power to the gas burner and set the thermostat to the lowest temperature setting. 3. Remove the upper door from the gas burner. 4. Turn the gas control lever to the Off position. 5. Disconnect the wires from the gas valve, ignitor and flame sensor. 6. Using wrenches, separate the ground-joint union in the gas supply piping at the gas burner. 7. Remove the piping between the gas valve and the ground-joint union, if necessary. 8. Remove the four screws holding the burner assembly in place and remove the burner assembly. Be extremely careful not to damage the ignitor while removing the burner assembly. 9. Inspect the burners and clean them (if necessary) with a soft wire brush and/or the nozzle of a vacuum cleaner. Be extremely careful not to damage the ignitor while cleaning the burner. 10. Replace all parts in reverse order from which they were removed. 11. Follow the lighting instructions found on the gas burner door to return the unit to operation. Verify proper operation after servicing. vces-vuv-iom-3 ERV1100w with Gas Heat 23

24 Appendix A: ERV1100w Overall Dimensions [343] [181] [150] Notes: Dimensions in [ ] are millimeters. Direction of airflow B A [676] [76] [134] TOP VIEW [267] D C Power connection Control wire connection C Combustion air inlet collar A B D Gas exhaust vent Gas heat condensate drain E F CW/Dx condensate drain Access Opening Table Connection Sizes 2.0 [51] 1.0 [25] 3.0 [76] 2.0 [51] 1.0 [25] 0.75 [19] Supply air [305] Outdoor air OA [1,927] F Exhaust air Return air EA [1,049] [775] [438] 7.500" [191] [472] LEFT VIEW FRONT VIEW RIGHT VIEW BACK VIEW [68] [74] [813] A B E [279] [657] [64] [98] [809] Figure A1: ERV1100w unit dimensions vces-vuv-iom-3 ERV1100w with Gas Heat 24

25 Appendix B: ERV1100w Components Supply air plenum Air conditioning coil (optional) Control box DDC controller/keypad Interconnection terminals Energy recovery module Exhaust blower assembly Figure B1: ERV1100w unit components Removable door for venting installation Sealed venting chase Gas burner module Opening for gas piping Supply blower assembly Filter access Description of Gas Components Figure B2 shows the location of each of the functional components described below. If any components of the gas burner must be replaced, use only factory authorized replacement parts. Flame Rollout Switch The flame rollout switch verifies that the burner flames are drawn into the heat exchanger tubes. If the burner flames are not properly drawn into the heat exchanger, the flame rollout switch will open. The circulating air blower (and combustion blower, if connected) will continue to operate if the flame rollout switch opens. Pressure Switch The pressure switch verifies that the inducer is drawing the combustion gases through the heat exchanger. Combustion air intake Flame rollout switch(es) Ignitor (not shown) Gas valve Pressure switch Control board Low voltage transformer Front header box Blower door switch Condensate drain tube Figure B2: ERV1100w burner components Exhaust vent Burner view port Flame sensor (not shown) Supply air limit switch Inline drain assembly Induced draft blower Vent safety switch Circulating air blower assembly Vent Safety Switch The vent safety switch shuts the gas burner down if the vent becomes blocked or restricted. Flame Sensor The flame sensor acts to prove that flame has carried over from the ignitor to the opposite end burner. If no flame is sensed, the gas burner will shut down within seven seconds of ignition. Supply Air Limit Switch The supply air limit switch prevents the air temperature leaving the gas burner from exceeding the maximum allowable outlet air temperature. Gas Valve The gas valve controls the flow of gas to the burners. When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold. A twostage or modulating unit will light in high fire and turn down as required. vces-vuv-iom-3 ERV1100w with Gas Heat 25

26 Appendix C: ERV1100w Rough-in (Ducting Only) Fresh air from outside Exhaust air to outside Install drain with water trap as shown Condensate drain with trap Notes: 1. For ducted supply units, the Manufacturer recommends elbows to be smooth radius type or equivalent to maintain low external pressure losses due to ductwork. 2. All duct connections must be sealed with a commercial brush-on sealant or equivalent. Figure C1: ERV1100w rough-in vces-vuv-iom-3 ERV1100w with Gas Heat 26

27 Appendix D: Remote Occupant Interface The BacStat is connected to the unit using a four-conductor cable. Shielded cable should be used for the BacStat wiring and standard thermostat installation practices should be used. Avoid mounting the BacStat near any sources of heat or in places where airflow is restricted. The BacStat should be accessible to the occupant. The BacStat wires must run to the control terminal strip inside the Venmar CES unit. This terminal strip may have a wide variety of hardware and networking outputs (depending on the unit type and its configuration), but the BacStat connection is always clearly marked. The drawing below shows the BacStat wiring for a typical ERV1100w hydronic unit. 10K ROOM THERMISTOR CONTROL OUTPUTS + 24 VAC 24 VAC W Y 1 2 AUX. POWER AUX. HEAT AUX. COOL 10K ROOM THERMISTOR CHILLED WATER VALVE HYDRONIC/STEAM VALVE 1 2 CONTROL OUTPUTS + 24 VAC AUX. POWER 24 VAC 9 10 NET + NET BACNET MS/TP RS W Y PWR 24V AUX. HEAT AUX. COOL CLASS 2 VOLTAGE Note: Use of 24 VAC circuit requires isolating contacts (ex. thermostat) to prevent interconnection of Class 2 outputs. BACSTAT II ROOM SENSOR GND COM NET + BACSTAT CONNECTION ONLY! Figure D2: Room sensor 10K thermistor + RS NET NET + NET BACNET MS/TP RS-485 N L2 L1 Ground Figure D1: Remote occupant interface CLASS 2 VOLTAGE Note: Use of 24 VAC circuit requires isolating contacts (ex. thermostat) to prevent interconnection of Class 2 outputs. L1 L2 N High voltage terminals Notes: 1. Fused disconnect switch supplied by Installer VAC/120/1/60 requires a neutral wire to be run with L1 and L2. 3. For 120/1/60 volt units, L2 is not required. Figure D3: Single-phase power supply wiring vces-vuv-iom-3 ERV1100w with Gas Heat 27

28 Appendix E: Gas Burner Wiring Diagram BLUE BLUE BLUE BLUE BLUE FLAME ROLLOUT SWITCH VENT.SAFETY. SWITCH FLAME ROLLOUT SWITCH (optional) FLAME ROLLOUT SWITCH (optional) BLOWER DECK SWITCH (optional) SUPPLY.AIR LIMIT SWITCH PRESSURE SWITCH BLUE BLUE ORANGE ORANGE WHITE BLACK WHITE.(NEUTRAL) BLACK.120V GROUND (from.unit.control.box) GREEN JUNCTION BOX BLOWER.DOOR SWITCH From.unit control.box ROOM.THERMOSTAT R Y G W TRANSFORMER WHITE.W/BLK.STRIPES BLACK.W/.WHITE.STRIPES WHITE 24.V 120.V BLACK AIR.CONDITIONER CONDENSING.UNIT FLAME.SENSOR C Y RED R C Y G W COM 24V AMP.FUSE BLOWER.OFF TWIN FLAME STATUS BLACK 3.OR.4.SPEED.MOTOR To.unit control.box Two-stage.option GAS VALVE YELLOW BROWN NEUTRALS EAC C H MH L ML HUM IGNITOR HUM M1 M2 M3 HEAT COOL EAC XFMR L1 WHITE RED ORANGE BLUE BLACK R INDUCER C BLACK BLACK BLACK BLACK RED ORANGE BLUE BLACK WHITE 6 MOTOR PLUG Fault Condition Power.on Limit.circuit.open Pressure.switch.stuck.open Pressure.switch.stuck.closed Ignition.failure.(check.ground) 115.VAC.&.neutral.reversed.or.no.ground False.flame.or.gas.valve.relay.shorted Power.off Fault Condition Low.flame.sensor.signal Flame.present Figure E1: ERV1100w gas burner wiring STATUS RED LIGHT ON 1.FLASH 2.FLASHES 3.FLASHES 4.FLASHES 5.FLASHES Continuous OFF FLAME YELLOW LIGHT Continuous Flash ON If.any.of.the.original.wire.as.supplied with.the.gas.burner.must.be.replaced,.it must.be.replaced.with.wiring.material having.a.temperature.rating.of.at.least.105 C. Legend Field.wiring: Factory.wiring: Low.voltage High.voltage vces-vuv-iom-3 ERV1100w with Gas Heat 28

29 Appendix F: Electrical Data Table F1: 120 VAC ERV1100w Gas Amount of Heat Input mca mop kw Input (Btu/hr) AC Option 3 Ton kw Btu/hr 40 mbh gas , , mbh gas , ,000 vces-vuv-iom-3 ERV1100w with Gas Heat 29

30 Appendix G: Gas Flow Rate Table G2: Gas Flow Rate (cubic feet per hour) Time for One Revolution (Seconds) Cubic Feet per Revolution of Meter ,800 3, ,500 3, ,286 2, ,125 2, ,000 2, , , , , , , , , , vces-vuv-iom-3 ERV1100w with Gas Heat 30

31 Appendix H: Equipment in a Confined Space Vent or chimney Ventilation louvres at each end of the attic Vent or chimney Air duct must be at least 1 sq. in. [6.45 sq. cm] per 4,000 Btuh of total input rating. 12 [305 mm] maximum See Note A below Attic insulation Ducts must extend above attic insulation Air duct must be at least 1 sq. in. [6.45 sq. cm] per 4,000 Btuh of total input rating. 12 [305 mm] maximum Water heater ERV1100w 12 [305 mm] maximum Note A: Each opening must be at least 100 sq. inches [ sq. cm] or 1 sq. inch [6.45 sq. cm] per 1,000 Btuh of total input rating, whichever is greater. See minimum area per table. Total Input Rating (Btuh) 40,000 60,000 Minimum Free Area (Each Opening) 100 sq. in. [ sq. cm] 100 sq. in. [ sq. cm] Round Duct Diameter 12 [305 mm] 12 [305 mm] Figure H1: All combustion air drawn from inside Water heater Total Input Rating (Btuh) 40,000 60,000 ERV1100w Minimum Free Area (Each Opening) 10 sq. in. [64.52 sq. cm] 15 sq. in. [96.77 sq. cm] Round Duct Diameter 4 [102 mm] 5 [127 mm] Figure H3: All combustion air drawn from the outdoors through vertical ducts (from ventilated attic) Vent or chimney Ventilation louvres (each end of the attic) Vent or chimney ERV1100w Alternate air inlet Outlet air Water heater Inlet air See Note A below 12 [305 mm] maximum 12 [305 mm] maximum Water heater ERV1100w Note A: Each opening to the outside must be at least 1 sq. inch [6.45 sq. cm] per 4,000 Btuh of total input rating. Ventilation louvres for unheated crawl space Note: Air openings shall each have a free area of not less than one square inch [6.45 sq. cm] per 4,000 Btuh of the total input rating of all equipment in the enclosure. Figure H4: All combustion air drawn from the outdoors through ventilated crawl space and ventilated attic Vent or chimney Total Input Rating (Btuh) Minimum Free Area (Each Opening) Round Duct Diameter 40,000 60, sq. in. [64.52 sq. cm] 15 sq. in. [96.77 sq. cm] 4 [102 mm] 5 [127 mm] Figure H2: All combustion air drawn from the outdoors through an exterior wall ERV1100w Air duct Air duct Air duct must be at least 1 sq. in. [6.45 sq. cm] per 2,000 Btuh of total input rating. Water heater Total Input Rating (Btuh) 40,000 60,000 Minimum Free Area (Each Opening) 20 sq. in. [ sq. cm] 30 sq. in. [ sq. cm] Round Duct Diameter 5 [127 mm] 6 [152 mm] Figure H5: All combustion air drawn from the outside through horizontal ducts vces-vuv-iom-3 ERV1100w with Gas Heat 31

32 Appendix I: Venting Options 5/8 [16 mm] Inlet Exhaust See Minimum Clearances to Combustible Material chart Combustion Straps or other suitable supports at minimum 5 foot [1.5 m] intervals Coupling Seal/caulk around pipe at building Offset with exhaust pipe for adequate dimensional clearance PVC or ABS pipe Upward pitch ¼ [6 mm] per foot outlet exhaust vent First support placed as close to the appliance connection as possible Exhaust vent Wall 7 [178 mm] 90 elbow 12 [305 mm] Normal snow level Figure I1: Horizontal venting Straight Neoprene coupling with 2 hose clamps* (optional not shown) * These couplings are field supplied and can be used if the installation requires breakable connections in the piping. Note that a maximum of two couplings per pipe are allowed. Support system on vertical rise below joints Support system with first support as close to the appliance as possible 5' [1.5 m] Combustion air pipe Exhaust vent Straight Neoprene couplings with two hose clamps* (optional not shown) Upward pitch ¼ [6 mm] per foot Cabinet Furnace front Figure I2: Vertical venting vces-vuv-iom-3 ERV1100w with Gas Heat 32

33 Appendix J: Air Pipe Clearances and Vent Termination Exhaust vent Option B Mounting kit facebpale secured to wall with screws Combustion air inlet Exhaust vent Option A 8 [203 mm] min. Exhaust vent Option C 7 [178 mm] min. 18 [457 mm] min. 36 [914 mm] max. 18 [457 mm] min. 36 [914 mm] max. 12 [305 mm] min. to normal snow level Grade level or normal snow Inlet Exhaust Figure J1: Exhaust and combustion air pipe clearances Exhaust vent 1 [25 mm] Elbow Combustion air intake 18 [457 mm] min. 36 [914 mm] max. A A Exhaust Plumbing vent roof boot (typ. both pipes) Figure J2: Vertical vent termination A = 12 [305 mm above roof or snow accumulation level vces-vuv-iom-3 ERV1100w with Gas Heat 33

34 Appendix K: DDC Keypad Reference Guide Unit Setup and Configuration Using the Keypad Controls Values are changed using the up and down arrow keys. Adjusting Room Setpoint Press the Thermometer key. The room setpoint will be displayed and may be altered using the up and down arrow keys. Pressing the Thermometer key again will enter the selected setting(s). Adjusting Date and Time Press the Clock key. Cycle through the time and date fields using the left and right arrow keys and adjust the values using the up and down arrow keys. Pressing the Clock key again will enter the selected setting(s). the value. Pressing the Schedule key again will enter the selected setting(s). Troubleshooting Quick Reference Guide Entering the Menu Mode To enter the menu mode, hold down the left and right arrow keys at the same time for a few seconds until the word Pin appears on the display. Enter the Pin number. At this point, the controller will enter the menu mode, displaying one of the three menus listed below. Selecting Menu and Sub-menus Refer to reference guide in Table K1. Use the number keys to select the appropriate menu and the left and right keys to alternate between the submenus. Setting the Schedule Press the Schedule key. Cycle through the daily on and Selecting Individual Parameters and Settings Refer to reference guide in Table K1. off times with the left and right arrow keys. Adjust the time with up and down arrow keys. To change the time Use the left and right arrow keys to cycle through the individual parameters and the up and down arrow keys to increment (ex. hours to minutes) hold the Occupied key down while using the up and down arrow keys to change change the available settings. Table K1: DDC Keypad Reference Guide Menu Sub-menu Parameter Settings Comments Manual Control Manual Mode Occupied ventilation Active/inactive Display Man Mode Occupied heating Off/stage 1/2/3/4 Unit will go into a standby Display Ctrl Only one mode may be Occupied cooling Off/stage 1/2/3 mode while user is in manual Button 1 on keypad manually active at any Unoccupied heating Off/stage 1/2/3/4 control of outputs. time Unoccupied cooling Off/stage 1/2/3 System Diagnostics Input Monitor OA temperature Value from sensor * Display only not adjustable Display IP Montr Display Diag Button 2 on keypad System will continue to operate normally while in diagnostic Display Sys Valu mode Mixed air temperature Value from sensor * Display only not adjustable Discharge air temperature Value from sensor * Display only not adjustable System Values Cooling controller Value from controller * Display only not adjustable Heating controller Value from controller * Display only not adjustable Cooling stage 0, 1, 2, 3 * Display only not adjustable Heating stage 0, 1, 2, 3, 4 * Display only not adjustable Defrost flag On/off * Display only not adjustable Free cooling flag On/off * Display only not adjustable Program ID ID # * Display only not adjustable System Configuration Setpoint Adjustment Free cooling setpoint Temperature Unoccupied cooling setpoint Temperature Display SP Adj Unoccupied heating setpoint Temperature OAD min position Temperature RAD min position Temperature Display Cfg Controller Settings Heating prop band % Button 3 on keypad Heating reset rate % Cooling prop band % Cooling reset rate % Display CO Setup * Recommend to power down Units Metric/US the unit after changing this setting. Dx cooling On/off Enables/disables Dx cooling. Exit Menus Button 5 on keypad Display Exit Exit Yes/no vces-vuv-iom-3 ERV1100w with Gas Heat 34

35 Appendix L: ECM Motor cfm Adjustment Procedure Step 1 Using a DMM set to measure VDC, record all current values for each of the Flo points. Measurement is made between Flo Com and the respective Flo test point. Record these values under Factory Set. Refer to Figure L1 to locate test points. Figure L1: ECM test points Step 2 If a voltage is present on Flo 0, that will be your low speed setting. If no voltage present on Flo 0 then Flo 1 is low speed. Each ascending Flo value corresponds to the next speed setting. Decrease cfm While measuring the Flo setting adjust the respective RP potientiometer counter-clockwise for that speed. A voltage decrease of 0.05 VDC will decrease the motor torque by one oz-ft. Increase cfm While measuring the Flo setting adjust the respective RP potientiometer clockwise for that speed. A voltage increase of 0.05 VDC will increase the motor torque by one oz-ft. A one oz-ft adjustment in motor torque will approximately increase/decrease the fan output by cfm. Record the new values set for each Flo setting under Field Set values. Table L1: ECM Motor Adjustment Values Factory Set Field Set Test Point Measured Measured Test Point Value Value Flo 0 Flo 0 Flo 1 Flo 1 Flo 2 Flo 2 Flo 3 Flo 3 Flo 4 Flo 4 vces-vuv-iom-3 ERV1100w with Gas Heat 35