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1. O O O00 OO BE OG O C OO D 9 S S 2U 18 SEW ISNA JSN d Els 16 Al IUe NO c ucdl EnergyX Control Board EXCB inputs from transducers and discrete inputs See Options and Accessories section The EXCB has relay analog outputs See Fig 7 and Table 7 and is equipped with a LCD screen The EXCB has a reset button that is used to force all the outputs and reset The EXCB board is the muscle of the ERV control system communication The EXCB continuously monitors input output channel NOTE Th hard j set throughout the information received from its inputs The EXCB receives G S sa 5 board Do not change these jumpers TF CTP EZ I 000000 20000 Q9CPEA2T FE OT 000000 0000 95 TE 2 1 ESI 000000 e e eee e e 4 SC EZI OHA PEZI s RR Fe T 666666 PAGE 6606 zma Ore eiim se IBIZ Te e R Le pre Kiel TRIST mens r3e 0 M 031 0 m 314 1234 0000 0000 1234 mo re s e R33 Fe e Re7 Le e 23 le Neira meme De R13 D13 e re Be
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7. 22 Exhaust Air Hood Removal 23 Outside Air and Exhaust Fan Replacement 23 Outside Air Fan Removal 23 Exhaust Fan Removal 25 EnergyX APPENDIX Appendix A Certified Dimension Drawings Appendix B Exhaust Fan Performance EnergyX Modulating Volume 20 25 Ton Units Appendix C Electrical Data Table 8 48HC with ERV Unit Wire Fuse or HACR Breaker Sizing Data Table 9 48HC with ERV and Factory Installed HACR Breaker w d Mee ack oa ates Table 10 48HC with ERV and 2 Speed Indoor Fan Option Table 11 48HC with ERV Factory Installed HACR Breaker and 2 Speed Indoor Fan Option Table 12 50HC with Electric Heat and ERV Unit Wire Fuse or HACR Breaker Sizing Data Table 13 50HC with Electric Heat ERV and Factory Installed HACR Breaker Table 14 50HC with Electric Heat ERV and 2 Speed Indoor Fan Option Table 15 50HC with Electric Heat ERV Factory Installed HACR Breaker and 2 Speed Indoor Fan Option Appendix D I O Flex 6126 Controller Appendix E Carrier BACview Virtual BACview Commissioning u aa huahua KR a as ENERGYX UNIT START UP CHECKLIST SAFETY CONSIDERATIONS Improper installation adjustment alteration service maintenance or use can ca
8. C11471 Fig 10 Segment Retaining Brackets 6 Gently lift segment outward 7 Close segment retaining latches and rotate wheel 180 to remove next segment Follow this pattern to remove all segments and keep wheel balanced 8 To install the wheel segments hold the segment as vertically as possible and centered between spokes insert nose of segment downward between the hub plates See Fig 11 C11472 Fig 11 Segment Removal 20 NOTE The face of the segment with the imbedded stiffener vertical support between nose and rim end of segment must face the motor side of the cassette See Fig 12 Imbedded Stiffeners 10 11 12 13 C11473 Fig 12 Imbedded Wheel Stiffeners shown from motor side of wheel assembly Ease the segment downward until its outer rim clears the inside of the wheel rim Press the segment inward against the spoke flanges Close and latch segment retaining brackets to the pos ition shown in Fig 10 Make certain the retaining bracket is fully engaged under the catch Slowly rotate by hand the first installed segment to the bottom of the cassette and then install the second segment opposite the first Repeat this sequence with the two installed segments rotated to the horizontal position to balance the weight of installed segments Continue this sequence with the remaining segments as necessary When complete close access door and remove lock out and tag out
9. 2 34 375 in x 24 5 in x 1 in INSTALLATION An EnergyX unit is installed as a single piece unit To install an EnergyX unit follow the base rooftop unit installation instructions with the following exceptions and additions Install Roofcurb Vertical Airflow Configurations The EnergyX unit uses the standard HC base unit roofcurb No extra curb support rails or extensions are required See the unit nameplate for model number designation Refer to the base rooftop installation manual and Install Hold Down Brackets below for roofcurb instructions Ductwork must be attached to the curb Horizontal Airflow Applications EnergyX units with a horizontal return and supply air configuration require a field installed horizontal curb adapter kit Refer to the base rooftop installation manual and the horizontal curb adaptor kit manual for roofcurb instructions Rig and Place Unit on Curb Inspect the EnergyX system for damage File a claim with the shipping company if shipment is incomplete or damaged p CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage All panels must be in place when rigging Unit is not designed for handling by fork truck Install Hold Down Brackets Target curbs and curb adapters include hold down brackets provided by the roof curb manufacturer Brackets must be installed on curb and attached to unit base rails See Fig 1 for details If using E
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11. C13023 Fig 1 MRT ERY Hold Down Brackets Location and Installation EnergyX de base comme indiqu au d tail A de l appareil le haut de l appareil L DETAIL A VOIR D TAIL A MAX WEIGHT POIDS MAXIMUM LB LIVRES 48HC17 WITH ERV A CAUTION NOTICE TO RIGGERS A AVERTISSEMENT REMARQUE A L ATTENTION DES MONTEURS ALL PANELS MUST BE IN PLACE WHEN RIGGING TOUS LES CAPOTS DOIVENT ETRE EN PLACE AVANT LE LEVAGE UNIT IS NOT TO BE RIGGED WITH CHAINS THROUGH BASE RAILHOLES NE PAS PASSE LES CHAINES AU TRAVERS LES TROUS DU GLISSIERE DE BASE POUR GREE L UNITE Hook rigging shackles through holes in base rail as shown in detail A Holes in base rails are centered around the unit center of gravity Use wooden top skid when rigging to prevent rigging straps from damaging unit Accrocher les manilles des lingues de levages dans les trous situ s dans le rail Les trous pratiqu s dans le rail de base sont centr s autour de centre de gravit Utiliser des cales en bois lors du levage pour viter que les lingues n endommagent PLACE ALL SEAL STRIPS IN PLACE BEFORE PLACING UNIT ON ROOF CURB 1676 INSTALLER TOUTES LES BANDS D ISOLATION EN PLACE AVANT DE 66 PLACER L APPAREIL SUR LE REBORD DUCT END PASSAGES CONDUITES DE TOIT DETAIL A DETAIL A 1328 48HC20 WITH ERV 1328 48HC24 WITH ERV 1532 48HC28 WITH ERV 1532 50HC17 WITH ERV
12. p i 1 Sets absolute minimum OA CFM for ventilation CFM CFM F F OATMPSPT OA Tempring SAT Setpoint 35 to 80 5 Sets target Supply air temperature during tempering OACFM_K Outside Air CFM k Factor 0 8 to 1 2 0 Sets outside air curve correction factor EXCFM_K Exhaust Air CFM k Factor 0 8 to 1 2 1 0 Sets exhaust air curve correction factor EFB_ENBL ERV Fan Boost Enable No Yes Tells RTU to adjust fan speed for low outside air CFM Requires an Economize which is not available for Target EnergyX units at this time 10 Table 4 Status Points ERV Writes these Values OAU_RUN OAU System Run State High level ERV state OAU_MODE OAU Operating Mode 0 Off ERV s current operating mode 1 ERV DCV 2 Free Cooling 3 OA Tempering 4 Defrost 5 Test 6 Ext Mode 1 7 Ext Mode 2 8 Ext Mode 3 ORULLAT Requires an Economize which is not available for Target EnergyX units at this time 11 EnergyX 20 and 25 Ton Modulating ERV control ventilation DCV operation The modulating ERV will operate based on occupancy and the rooftop s operating mode the following sections explain operation in detail Refer to Fig 4 for the overview flow diagram of a modulating ERV operation The modulating ERV is an intelligent ERV with variable speed fan motors The ERV can provide a variety of volumes of outside air and offset it with different exhaust speeds CO sensors can also be tied into it for Demand ERV Mode 7
13. T ONLY LED H we H GRN OCCUPANCY AND REMOTE SHUTDOWN INAL BOARD ARE CUT WHEN ADDING POWER EXHAUST HEAT STAGE Z SUPPLY Faw L RED EQUIP GR TARGET FIOP DDC NAL BOARD SCHEMATIC LAYOUT DOES NOT MATCH ACTUAL TERMINAL BOARD Fig 32 Wiring Diagram 48HCD 24 28 with I O Flex 6126 Controller 52 501M501063 6 C12788 8g F9010SW10S xAB1ou3 1 310N 318 QHYOB TWNINU3I 812 038 wa 14805 nag 1 3905 1009 J mg z 39615 1009 E 1 3905 iva aus Im D mm e vun
14. protected against voltage transient and surge events Status indicators LEDs indicate status of communications running errors and power LED indicators for transmit receive for Port 1 and Port 2a and for each of the 12 outputs 20 to 140 F 29 to 60 C 10 95 relative humidity non condensing 1113 46 in 30 cm x 5 in 12 7 cm x 19 46 in 4 cm BACnet Support Conforms to Advanced Applications Controller B AAC Standard Device Profile as defined in ANSI ASHRAE Standard 135 2004 BACnet Annex L Listed by UL916 Canadian Std C22 2 No 205 m1983 CE FCC Part 15 Subpart B Class A 51 EnergyX MID TIER YAC CONTROL 208 230V 460V 575V 3 OFM DUAL COMPRESSOR 5078501847 CTB TERMINAL BOARD SEE NOTE 1 RED RED BRN SEE NOTE 3 IFM OL aana ORED o RED n d 33 e 1 Dhon a poe gayi El we EE daf H 1 GOL
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17. weus INIYANI 140 D Us me mm H 23395 200 4011 1398V1 IVBLOSWLOS C12789 50HC 24 28 with I O Flex 6126 Controller iagram ing D iri W Fig 33 53 To Address the UO Flex 6126 The I O Flex 6126 s two rotary switches determine the I O Flex 6126 s MAC address when it is place on the BACnet ARC156 or BACnet MS TP network The rotary switches define the MAC address portion of the device s BACnet address which is composed of the network address and the MAC address They also set the slave address on a Modbus or N2 network when less than 100 1 If the I O Flex 6126 has been wired for power pull To Wire for Power p CAUTION EQUIPMENT PERFORMANCE HAZARD Failure to follow this caution may cause equipment to not work properly The I O Flex 6126 has an operating range of 21 6 Vac to 26 4 Vac If voltage measured at the I O Flex the screw terminal connector from its power terminals labeled Gnd and Hot The controller reads the ad dress each time you apply power to it Using the rotary switches set the controller s address 6126 s input terminals is outside of this range the I O Flex 6126 may not work properly Do not power pilot relays from the same transformer that powers the I O Flex 6126 EnergyX Set the Tens 10 s switch to the tens digit
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19. 20 amp 25 Ton Modulating ERV 12 OCCUPANCY cred Re AERA EG RC DE 13 Modes of Operation 111111 13 Off Mode 143 Rr ENEE EENS 13 Test Mode SEELEN NEE Rr Rer 13 Defrost Mode 13 ERV DCV Mode 13 Exhaust Control 13 TROUBLESHOOTING 13 Complete ERV Stoppage 2 11111 13 On board Pressure Transducers 14 Wheel Status option 14 EnergyX Control Board LEDs 14 MAJOR SYSTEM COMPONENTS 14 EnergyX Control Board EXCB 17 Enthalpy Wheel 411 41111 18 Modulating Fan 18 Options and Accessories 18 Frost Protection factory installed option only 18 Wheel Motor Status option 18 SERVICE amp MAINTENANCE 19 Cleaning ie giya ree e ERA eee Ed ra 19 Wheel and Segment Cleaning 19 lulio EET 19 Outdoor Air Inlet Screens 19 Lubticatiotr aa 19 Wheel Drive Adjustment 19 Wheel Air Seal Adjustment 19 Wheel and Segment Removal Installation 20 Wheel Segment Removal Installation 20 Whole Wheel Removal Installation 36 wheels 21 Outside Air and Exhaust Hood Removal 22 Outside Air Hood Removal
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21. OO Remove Fasteners 8 Places the dividing wall by access through the door of the unit See Fig 18 5 Disconnect connectors PL120 and PL122 as well as the power wires for the exhaust fan motor from the wiring harness inside the air chamber of the EnergyX unit NOTE Tilt the fan assembly front panel to fit it through the hood opening 6 Pull the exhaust air fan out through the hood opening See Fig 18 NOTE Tilt the fan assembly to fit its back panel through the opening in the dividing wall NOTE Illustration shows options that may not be on all units C13030 Fig 18 Exhaust Fan Assembly Fastener Locations 25 NOTE To meet building codes aust hood si xAB1ou3 Removal Fig 19 Exhaust Fan Assembly APPENDIX Appendix A Certified Dimension Drawings Appendix B Exhaust Fan Performance Curves EnergyX Modulating Volume 20 and 25 Ton Units Appendix C Electrical Data Table 8 48HC with ERV Unit Wire Fuse or HACR Breaker Sizing Data Table 9 48HC with ERV and Factory Installed HACR Breaker Table 10 48HC with ERV and 2 Speed Indoor Fan Option Table 11 48HC with ERV Factory Installed HACR Breaker and 2 Speed Indoor Fan Option Table 12 50HC with Electric Heat and ERV Unit Wire Fuse or HACR Breaker Sizing Data Table 13 50HC with El
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25. 2 1067 mn A ZA A i ON pd br z a 60 in p 1524 mm ies 74 bo 36in in s 914 mm gt Y a ly I z IA D a San Z vi _ 1295 mm gt u Ca SCH A gt A E R c sin x Pau P di 1893 mm iN 36in A d SA 914 mm lt C13024 Fig 3 Clearances for ERV on Size 24 amp 28 HC Base Unit EnergyX Make Electrical Connections See the base unit name plate for the ETL certified singlepoint electrical values and component electrical information See the base unit control box and EnergyX access doors for the electrical wiring diagrams specific to each section Main Power Follow all base unit installation instructions using electrical values shown on unit nameplate only one main power supply is required The EnergyX base rooftop unit and energy recovery module is ETL listed as a single point power supply only On some voltage ERV s there is a step down transformer that is factory supplied to power components that are not line side voltage Field wiring or alteration of these components is neither required nor desired p CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage Some electric heat modules require a dual point electrical service connection independent from all other electrical circuits in the unit Consult the unit installation instructions unit wiring diagrams and or electric heater installation instructions
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29. ERV Configurations Read OAU_TYPE Outdoor Air Unit Type 0 No OAU 0 no FIOP Defines what kind of OAU is 1 ERV Module 1 FIOP EXv2 installed 2 Economizer 3 Pwr Exhaust 4 OA Monitor 5 100 OA unit 6 EXv1 ERV OAFANCRV Outside Air Fan Curve 0 to 999 i Determine what outside air fan 11 17 20 and no econ PEFANCRV Exhaust Air Fan Curve 0 to 999 12 24 28 UNOCCRUN OAU Unoccupied No Yes Tells OAU to run in unoccupied Operation mode curve to use 04 1ph and econ Determine what exhaust air fan 04 3ph and econ curve to use 04 1ph and no econ 04 3ph and no econ 05 06 1ph 05 06 3ph 0 0 NO OU BO Ios 10 17 20 and econ FATALOAU Shut Down on Fan Failure No Yes Tells OAU to shut off if one of it s fans fail MODWHEEL Modulating Wheel Install No Yes Determine if the OAU s wheel is a modulating one MINOACFM Minimum Outside Air CFM 0 to 32000 Sets Design OA CFM for ventilation MINDCVSP Min DCV Outside Air CFM 0 to 32000 PEX CTL Power Exhaust Control 0 offset CFM Determine how to control the 1 BP exhaust fans EXOFFSET Power Exhaust CFM Offset 17000 to 17000 CFM 200 Sets offset CFM setpoint of exhaust based on intake OAU_BPSP Building Pressure Setpnt 0 25 to 0 25 inH2O 0 05 Sets required building pressure OATEMPER Outside Air Tempering Disable Enable Disable Determine if there is tempering heater installed OATMPLOC OA Tempring Lockout Temp 0 to 80 Sets the outside temp and below to allow tempering
30. Refer to the troubleshooting section for details on communication failures Table 2 shows the I O Flex 6126 points that the ERV monitors for operation and a brief description of their functions Table 3 shows the I O Flex 6126 points that the ERV uses for its configurations and a brief description of each Table 4 shows the I O Flex 6126 points that the ERV writes to based on its running status Table 2 Inputs Points the ERV Read OCCUPIED Currently Occupied NoYes Determine if RTU is occupied IDFSTATE Indoor Fan State Off On Determine if the RTU indoor fan is running FANSPEED Commanded Fan Speed RE MED Determine if the RTU indoor fan is running A IAQ Level sensor px fT Space CO2 sensor level PPM IAQIN IAQ Level switch Low High Determine if CO2 is high or low o IAQANCFG IAQ Analog Input Config 0 No IAQ Tells if a sensor is installed for DCV or 1 DCV override 2 Override IAO 3 Ctrl Min Pos IAQANFAN IAQ Analog Fan Config 0 Never Tells if the ERV can run during 1 Occupied unoccupied for high CO2 2 Always IAQINCFG IAQ Switch Input Config 0 No IAQ Tells if a switch is installed for DCV or 1 DCV N O override 2 DCV N C 3 Override N O 4 Override N C IAQINFAN IAQ Switch Fan Config 0 Never Tells if the ERV can run during 1 Occupied unoccupied for high CO2 start ventilating more vent occurs SWHEEL o UWmesTes Je o restwneaiwnientestmode EnergyX Table 3 Configurations
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32. Test User sets ERV to desired values for TEST testing purposes RTU in test OAU OA Fan Speed Test mode OAU PE Fan Speed Test OAU Wheel Test ERV Mode Defrost Is there Wheel On frost on the OA CFM lt 0 wheel Ex CFM Min CEM in effect Ex CFM offset VENT RTU in Heat or Vent Is unit occupied and IDF on ERV Mode ERV or DCV Mode Wheel On OA CFM Min CFM Ex CFM OA CFM Ex CFM offset ERV Mode OFF Wheel off OA CFM 0 Ex CFM 0 Notes 1 Min CFM represents the minimum outside air CFM requirement based on CO values and setpoints 2 Occupied also means being in the unoccupied period but configured to run 3 Requires factory installed Frost Protection option C13025 Fig 4 Modulating ERV Control amp Operation Flow Chart 12 Occupancy The ERV will not be allowed to run unless it is determined to be occupied The ERV monitors the rooftop s occupancy point to determine when it is occupied The ERV watches the rooftop s indoor fan state point to know when its indoor fan has started When the rooftop is occupied and its indoor fan is on the ERV is considered to be occupied and allowed to run The ERV can also operate during the rooftop s unoccupied period If the ERV is configured for unoccupied operation then it will ignore the building occupancy of I O Flex 6126 and allow occupancy any time the rooftop fan is on Modes of Operation The ERV has 3
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34. basic functions Auto Off or Test These are defined as System run states and displayed in the OAU run status menu The ERV will always operate in one of the following operating modes depending upon the mode and outside conditions Off ERV DCV Free Cooling OA Tempering Defrost or Test The ERV monitors to determine the rooftops operating mode The values tell the ERV what the rooftop operating mode is in a numeric form These modes are described below Off Mode The ERV will be set to the Off mode whenever the rooftop indoor fan is turned off ERV is unoccupied or if communication fails During Off Mode the wheel outside air fan and exhaust fan will be off Test Mode If at any time during operation the rooftop is put in Service Test mode the ERV will be set to Test Mode Refer to Start Up section for Test mode operation Defrost Mode Defrost Mode is only available when the optional Frost Protection is factory installed in the ERV The ERV will be set to defrost mode any time the ERV wheel is running and frost is detected on the wheel Defrost Mode runs for at least 2 minutes but continues to run until the frost is removed The frost protection device senses a pressure differential across the wheel and trips when that differential is greater than the setpoint default 2 0 in wc For information on the frost protection device refer to the Major Component section When in Defrost Mode the outside air fan will ra
35. for verification Control Power Follow all base unit installation instructions for low voltage wiring The ERV control board is factory wired into the base unit communications All external control wires still connect to the RTU terminal strip as in the base unit installation instructions See Appendix D of this manual for details on connections for the I O Flex 6126 controller Base Unit Components Follow the base unit installation instructions to install all other base unit components including but not limited to flue hoods condensate trap and other accessory devices START UP The EnergyX unit is operated in coordination with the base rooftop unit Follow the base unit instructions and Controls book for proper start up with addition of the following Start Up Check List Use the EnergyX Start Up checklist see page 63 in conjunction with the base unit Start Up checklist from the base Controls book Fill in all blank data entries that are applicable to the exact unit being installed The ERV model and serial numbers are printed in the ERV control box Save the checklist for future service and maintenance use It is recommended that a copy of the checklist be left with the unit in the literature slot on the base unit control box access door Base Unit Evaporator Fan First follow the base unit instructions to balance the RTU indoor fan The ERV fans should be off during base unit fan set up Before start up a
36. improve the life of the wheel transfer segments Once the wheel is exposed to oils tars or greases in either the supply or exhaust air streams these pollutants deposit on the rotary surface which they become sticky and begin to attract and hold the dust particles that previously passed thru the wheel Over time this particle build up can lead to blocked airflow passages loss of recovery excessive pressure drop through the wheel and loss of energy savings 1 Follow steps for wheel and segment removal to remove the affected energy transfer matrix segments 2 Gently brush the wheel face to remove loose accumulated dirt 3 Wash the segments with a non acid based evaporator coil cleaner or alkaline detergent solution Non acid based coil cleaner such as KMP Acti Clean AK 1 concentrate in a 5 solution has been demonstrated to provide excellent results DO NOT use acid based cleaners aromatic solvents temperatures in excess of 170 F or steam Damage to the wheel will result 4 Soak the wheel and or segments in the cleaning solution until all grease and tar deposits are loosened An overnight soak may be required to adequately loosen heavy deposits of tar and oil based contaminants 5 Internal heat exchange surfaces may be examined by separating the polymer strips by hand Note some staining of the desiccant may remain and is not harm ful to performance 6 After soaking rinse the dirty solution from the wheel segmen
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38. test mode If you do not turn off the test mode the ERV will not operate properly Turn off the TEST mode on the top of the ERV TEST screen by setting LCD LOCAL FACTORY TEST to NO see Fig 48 as BACview Z77EACTORY TEST LGD LocAn FACTROY TEST NO LED_5_OADMER OFF Lena WHEEL 0 LCD 8 OAFAN ong LCD 8 EXFAN ang Lena OAHEAT ons Zero Press Sensor for CFM STATION Enable Zero Pressure Logic YES FACTORY TEST MUTE FN C12812 Fig 48 ERV Test Mode OFF At this point you can simply disconnect from the I O Flex 6126 and the RTU will continue operating in AUTO mode 61 EnergyX Copyright 2013 Carrier Corp e 7310 W Morris St e Indianapolis IN 46231 Edition Date 01 13 Catalog No TAR ERV1 02SI Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Replaces New 62 ENERGYX UNIT START UP CHECKLIST To be used in conjunction with base Rooftop Unit Start Up Checklist Remove and Store in Job File RTU MODEL NO RTU SERIAL NO ERV MODEL NO ERV SERIAL NO DATE TECHNICIAN L PRE START UP insert checkmark in box as each item is completed VERIFY THAT ALL PACKAGING MATERIALS HAVE BEEN REMOVED FROM UNIT VERIFY INSTALLATION OF OUTDOOR AIR HOODS CHECK THAT AIR FILTERS ARE CLEAN AND IN PLACE ON SUPPLY AND EXHAUST OF ERV WHEEL CHECK THAT OUTDOOR AIR INLET SCREENS ARE IN PLACE VERIFY CONFIGURAITON VALUES FOR ELECTRONIC CONT
39. to 2 0 inWC and is factory preset to 2 0 inWC Changing this setting may cause false signal causing defrost mode when not needed Wheel Motor Status option The wheel motor status accessory can be installed in the field and consists of a wheel motion proxy sensor and a relay The wheel motion sensor is aimed at the wheel to detect rotation If the wheel does not rotate at the appropriate speed the sensor will open causing the rotation monitor relay to close a contact to initiate the wheel status alarm The motion sensor is factory set at the highest speed clockwise until stop and should not be changed Refer to the troubleshooting section for details on the alarms 18 SERVICE amp MAINTENANCE Refer to base unit s Service manual for base unit service and maintenance This section contains service and maintenance for just the ERV unit Cleaning Wheel and Segment Cleaning Wheel cleaning periodicity is application dependent Field experience shows that offices schools and other clean environments will often go 10 years before any build up of dust and dirt is noticed Other applications such as restaurants casinos and factory environments may experience fairly rapid build up of contaminants and may require multiple cleanings per year to maintain airflow and recovery efficiencies All air to air energy recovery devices will become dirty over time even with well maintained filtration Proper filtration usage and changes will
40. to apply power to unit Whole Wheel Removal Installation 36 wheels These wheels include the shaft and are secured to two wheel support beams by two flange bearings with locking collars Follow the steps below for removal and reverse for installation See Fig 13 WHEEL FLANGE HUB amp BEARINGS SHAFT Q SET SCREWS 2 EACH WHEEL SUPPORT BEAMS C11474 Fig 13 36 Wheel Mount 1 Loosen the two set screws on each to the two wheel bearings 2 Remove belt from pulley and position temporarily around wheel rim 3 Remove pulley side wheel support beam with bear ing by removing four support beam screws 4 Pull the wheel with the shaft straight out of the motor side wheel support beam and bearing Handle wheel with care 5 When replacing wheel be certain to tighten four bear ing set screws Premature bearing failure can occur if not set tightly 21 EnergyX Outside Air and Exhaust Air Hood Removal Outside Air Hood Removal 1 Turn off lockout and tag out electrical power to unit 2 Remove the hood by removing the seal tek screws along the perimeter of the hood See Fig 14 NOTE Even after all screws have been removed from entire perimeter of hood it will still be difficult to remove due to the gasket applied from original installation Take care not to damage the gasket If damage occurs use 9430 2300 gasket to replace before reattaching th
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45. 1328 50HC20 WITH ERV 1328 50HC24 WITH ERV 1532 50HC28 WITH ERV 1532 48HCD 24 T 1532 48HCD 28 T 1532 50HC 24 T 1532 50HC 28 T 1532 50HE502615 D NOTE Units with T in the model number are for Target only C12774 Fig 2 Rigging Label 48 50HC Size 24 28 Units With ERV Positioning Maintain unit clearances as listed as shown in Fig 3 for minimum distance from combustible materials proper airflow and service access Follow all local codes for proper clearances the local code requirements take precedence over any clearance listed in this document Contact your local Carrier representative for clearance obstructions and any potential resulting affect on unit warranty Follow all other curb rigging and positioning installation guidance in base rooftop unit installation instructions Exhaust Hood To meet certain specific codes some 25 ton units those going to Target stores within the U S have corrugated plastic panels covering the ends of the exhaust hood The panels are for shipping only Remove the panels for unit operation allowing exhaust to exit the sides of the hood pd RR a gt TE 42in
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60. ROLS II START UP REFER TO UNIT SERVICE MAINTENANCE MANUAL FOR START UP INSTRUCTIONS ELECTRICAL SUPPLY VOLTAGE L1 L2 L2 L3 L3 L1 ERV SUPPLY FAN 1 AMPS L1 L2 L2 L3 L3 L1 ERV EXHAUST FAN 1 AMPS L1 L2 L2 L3 L3 L1 Distribution Block on 575v units will be 460v TEMPERATURES OUTDOOR AIR TEMPERATURE OAT F dB Dry Bulb RETURN AIR TEMPERATURE SPT or RAT F dB F wB Dry Bulb Wet Bulb ERV INTAKE LEAVING AIR TEMPERATURE LAT F ERV EXHAUST AIR TEMPERATURE EXAT F GENERAL MINIMUM DAMPER POSITION SET TO 0 ERV MINIMUM VENTILATION POSITION PER JOB REQUIREMENTS VERIFY ENERGY RECOVERY WHEEL IS ROTATING VERIFY SUPPLY AND EXHAUST BLOWER FANS ROTATING IN PROPER DIRECTION VERIFY ALL EXTERNAL PANELS FULLY SHUT AND LATCHED VERIFY NO ACTIVE ALARMS FOLLOW ALL ACCESSORY START UP PROCEDURES III CONFIGURATION Used in conjunction with Base Unit start up configurations Minimum DCV Outside Air CFM Minimum Outside Air CFM Exhaust Air Offset CFM Building Pressure Setpoint Frost Protection Dial Setpoint 63 EnergyX Copyright 2013 Carrier Corp e 7310 W Morris St e Indianapolis IN 46231 Edition Date 01 13 Catalog No TAR ERV1 02SI Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Replaces New 64
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62. Sensor 1 Turn off the I O Flex 6126 s power 2 Pull the screw terminal connector from the RS sensor 3 Pull the screw terminal connector from the Rnet port 4 Partially cut then bend and pull off the outer jacket of the Rnet cable s Do not nick the inner insulation Outer jacket V Foil sheild 265 In Inner insulation 6 cm C12796 5 Strip about 25 inch 6 cm of the inner insulation from each wire 6 Wire each terminal on the I O Flex 6126 s Rnet port to the terminal of the same name on the RS room sensor NOTES If using shielded wire connect the shield wire and the ground wire to the Gnd terminal Maintain same polarity Rnet port wie IS enc Black D o Rnet em e ez 12V BACview QQOQOo or o 000 sa RE gt L 0 Dm E SE tuc C12797 7 Turn on the I O Flex 6126 s power 55 EnergyX Troubleshooting If you have problems wiring or addressing the I O Flex 6126 contact OEMCtrl Technical Support Communication LED s The LED s indicate if the I O Flex 6126 controller is speaking to the devices on the network The LED s should reflect communication traffic based on the baud rate set The higher the baud rate the more solid the LED s become Lights when power is being supplied to the controller NOTE The I O Flex 6126 is protected by internal solid state Polyswitches on the incoming power and network connections These Polyswitches are
63. Target National Account EnergyX System Factory Installed Energy Recovery 48 50HC WeatherMaster Commercial Rooftop Units 20 and 25 Nominal Ton Units with Puron R 410A Refrigerant and I O Flex 6126 Controls Supplemental Installation Instructions This document is a supplemental installation instruction for Target rooftop units with the EnergyX factory installed Energy Recovery Ventilator It is to be used with the base HC 20 amp 25 Ton rooftop unit Installation Instructions NOTE Read the entire instruction manual before starting the installation TABLE OF CONTENTS SAFETY CONSIDERATIONS 2 GENERAL deeg e pp am eR aea 3 Physical Data as asss RE Ra paga sansa 4 INSTALLATION iii wA 5 Install Roofcurb 5 Vertical Airflow Configurations 5 Horizontal Airflow Configurations 5 Rig and Place Unit on Curb 5 Install Hold Down Brackets 5 POS reor ta eo O woo 6 Make Electrical Connections 8 Main POWT osas wa xd rre ER agg cad ya 8 Control Powet c S cies ce eae ENN NEE ca gun 8 Base Unit Evaporator Fan 8 STARTUP 22 l Ec Dra ra e sd Dai 8 Start Up Check List 441 41111 8 Base Unit Components 8 OPERATING SEQUENCE 8 General ilice ee yr edo oec HER rar 8 Communications 8
64. ation from average voltage 100x Voltage Imbalance average voltage 49 Example Supply voltage is 230 3 60 A B C AB 224 v LA BC 231 v AC 226v 224 231 226 681 Average Voltage 3 3 227 Determine maximum deviation from average voltage AB 227 224 2 3v BC 231 227 4v AC 227 226 1v Maximum deviation is 4 v Determine percent of voltage imbalance Voltage Imbalance 100 x 227 1 76 This amount of phase imbalance is satisfactory as it is below the maximum allowable 296 IMPORTANT If the supply voltage phase imbalance is more than 296 contact your local electric utility company immediately EnergyX APPENDIX D I O FLEX 6126 CONTROLLER General This appendix details the installation and configuration of the I O Flex 6126 into the Building Automation System BAS The I O Flex 6126 is a general purpose controller It memory and removable terminals for I O connections Screw The I O Flex 6126 controller is factory mounted in the 48 50HC unit s main control box to the left of the CTB central terminal board See Figs 32 and 33 for location of the I O Flex 6126 control provides the communications circuity non volatile y LLL Universal BACnet vas nat sec VO Flex 6126 Contos Only CONTROL MODULE Evan o Selec Gnd 20 24VAC Ul 12 19 Gnd k 4 Ul 11 18 EE i Gnd 17 one Ul 10 16 y Power UI 09 15 On Gnd
65. e Dee sE je M JP5 F E o M JP3e C ua eres te meP e e ral eme PLa e_u Er e us D17 e k m o CR Di jee tomers e eiu BI ef Pe ue B eile e Um S NH S H ers Acco ul Sul Wa ao eed are e mir reo Beeeeeeeeeeeeeeeeeee eee o rasa ees exe Tee L LJ e ss e ecsee 1 ve o ren el ER e e e s u ET4 RI 00000 12345 S R16 R32 e M P7 ein3ile Dz e elezale R J18 t re rT 12345 e H w N e eese cere eese LCD Contrast J20 12345 A rv W e F57 e RSE Fe e e r le C11467 Fig 7 EnergyX Control Board EXCB 17 EnergyX Table 7 EXCB Input Output Connections POINT DESCRIPTION Download N A Power from TRANS Power to Relays Wheel Rotation Sensor Frost Switch Leaving Air Temp Exhaust Air Temp Wheel Relay OA fan speed signal N A EX fan speed signal N A Building Pressure Sensor Enthalpy Wheel The enthalpy wheel is the heat exchangers of the ERV It consists of several wheel segments aligned in a cassette assembly These are not filters but made of a desiccant material The wheel is rotated by a motor and belt no adjustments required When the wheel rotates it uses the building exhaust air to pre conditions the outside air as it passes through the wh
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67. e hood 3 Disconnect the green HIGH and yellow LOW tubes attached to the quick connects located inside the ERV Do NOT damage the tubes m d C13026 Fig 14 Outside Air Hood Removal 22 C13027 Fig 15 Exhaust Air Hood Removal Exhaust Air Hood Removal 1 Turn off lockout and tag out electrical power to unit 2 Remove the hood by removing the seal tek screws along the perimeter of the hood See Fig 15 NOTE Even after all screws have been removed from entire perimeter of hood it will still be difficult to remove due to the gasket applied from original installation Take care not to damage the gasket If damage occurs use 9430 2300 gasket to replace before reattaching the hood Outside Air and Exhaust Fan Replacement Outside Air Fan Removal 1 Turn off lockout and tag out electrical power to unit 2 Remove outside air hood see procedure on page 22 3 Disconnect the connector PL121 PL123 and the power wires for the outside air fan motor from the wiring harness inside the air chamber of the EnergyX 4 Remove the fasteners at each corner of the outside air fan that secure the outside air fan front panel to the dividing wall by access through the hood opening of the ERV See Fig 16 NOTE See instructions for removing the wheel and supply filters if more room is needed to access the outside air fan through the door for better maneuve
68. e supported when the assembly is extended from the unit chassis to avoid damage to wheel or unit ERV wheels on 20 and 25 ton units are segmented wheel assemblies To remove or installed the whole assembly simply side in or out the assembly noting the motor power plug Wheel Segment Removal Installation 1 Turn off lockout and tag out electrical power to unit 2 Open access door to the EnergyX module on back side of the unit 3 Slide the entire wheel assembly out until the necessary segment s of the wheel can be accessed Support the weight of the wheel assembly as necessary to avoid damage to wheel or unit A CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Weight of the installed segment will cause the wheel to accelerate in rotation as segments are removed Failure to maintain control of the wheel rotation while installing all segments could cause severe injury to fingers or hand caught between revolving spokes and the bearing support beam The handle of a tool such as a hammer should be inserted through spokes and above or below bearing support beams to limit rotation of unbalanced wheel See Fig 9 Hammer used as a stop C11470 Fig 9 Wheel Stop 4 Position one segment opening at the top of the cassette 5 Unlock and open the segment retaining brackets on both sides of the selected segment opening See Fig 10 Catch Pull Tab
69. ectric Heat ERV and Factory Installed HACR Breaker Table 14 50HC with Electric Heat ERV and 2 Speed Indoor Fan Option Table 15 50HC with Electric Heat ERV Factory Installed HACR Breaker and 2 Speed Indoor Fan Option Appendix D I O Flex 6126 Installation Guide Appendix E Carrier BACview Virtual BACview Commissioning 27 c JO T 3994S ANA pue pap SES YIM Sutlo0O JIJI JUOZ e durs pz OH8P 0c Sur 444219 e Mid ONY 1V3H SVO HIIM 9NT1002 E ZWI Sr 690 053H05 1 21812313 INOZ FIONIS PZ 309 Lou Sg Bei IN 1H9lH zi 821 02211 HLGIM Z 1 06 8r ano KIO ATE t2 v612 81838 sre rm DIN uv 310NVH gan vt ldd Q00H 3011 S100V EY EI U 9N11311 8000 1OWULNOJ jO 19NY1d122V WO JONVWHOJUJd LYVd 310111SN02 LON 100 ISIN3N0200 YO SINIMVYO 3S3HI 40 NOISSIMBDS 1N3SNOJ NILLIUM S NOIIVUOdNOD WATHHYJ LNOHLIM 0250 NO 03S015SIQ 38 LON TIIM SIN1LNO JHL IVHL NOTLIGNOD SS3udX3 IHL NOd Q383A1130 SI ONY NOIIVHOdNO H3INNV 30 11939084 3H SI IN3W0200 SIHI lazer ERUN AN asnovaas SJT901ONHJ1L
70. eel Modulating Fan The modulating ERV is equipped with direct drive variable speed plenum fans for outside air intake and exhaust air The motors have built in VFDs that accept a 2 10vdc signal from the EXCB This 2 10vdc signal is used by the VFD to determine the speed to run the motor at 0 10046 Each motor is capable of diagnosing problems within the motor to provide fan status The fan status switches are built into each motor and provide a feedback to the EXCB if a problem is detected The feedback signal is a discrete input that is normally open when closed the EXCB will initiate the motor status alarm Outside Air pressure Transducer J24 Exhaust Air pressure Transducer J25 Options and Accessories The modulating ERV has several optional factory installed options and field installed accessories Frost Protection Wheel Motor Status Filter Maintenance horizontal adaptor curb building pressure sensor and Outside Air Tempering Kit Refer to Table 7 for where these options wire into the EXCB Frost Protection factory installed option only Frost protection is a factory installed pressure sensor device which senses a differential pressure across the wheel This occurs if frost builds up on the wheel The sensor closes its contact when the pressure differential is greater than the setpoint When the EXCB reads the contact closer it will activate defrost mode The setpoint is a dial on the sensor is adjustable from 0 2
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72. highlight suggestions which will result in enhanced installation reliability or operation A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could cause personal injury or death Before performing service or maintenance operations on unit always turn off main power switch to unit and install lock s and lockout tag s Unit may have more than one power switch Ensure electrical service to rooftop unit agrees with voltage an amperage listed on the unit rating plate p CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may cause equipment damage This unit uses a microprocessor based electronic control system Do not use jumpers or other tools to short out components or to bypass or otherwise depart from recommended procedures Any short to ground of the control board or accompanying wiring may destroy the electronic modules or electrical components p CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing air conditioning equipment GENERAL This publication contains Installation Start Up Controls Operation Troubleshooting and Service information for the EnergyX Energy Recovery System factory installed on a 48 50HC 20 to 25 nominal ton rooftop unit This document is a supplemental installation i
73. ic ZES gt Brev FACTORY TEST MUTE FN C12808 Fig 44 Initial ERV Test Screen Emas BER File Configure Help BACview FACTORY TEST LCD LOCAL FACTROY TEST YES LED_8_OADMPR OFF LGD 8 WHEEL 0 Lena OAFAN LcD 8 EXFAN 0 LCD 8 OAHEAT b Zero Press Bensor for CPM BTATION Enable Zero Pressure Logic YES OR 10 CANCEL DECR it INCR ALARM MUTE FN C12809 Fig 45 LCD LOCAL FACTORY TEST set to YES Et lo xd Eile Configure Help BACview Z77TFACTORY TEST LGD LOCAL FACTROY TEST YES LGD 8 OADMPR OFF LED 8 WHEEL Sr ben ga OAFAN 108 LED_8_EXFAN 181 LGD 8 OAHEAT 0 Zero Press Sensor for CFM STATION Enable Zero Pressure Logic ZES OR JI CANCEL J DECR 1t INCR C12810 Fig 46 ERV Output Values Entered 60 To see the effect on the CFM readings your test values are having scroll down the screen and look at the current Flow readings see Fig 47 EDITI R x 7 as File Configure Help LGD 8 OAHEAT 8018 Zero Press Sensor for CFM STATION Enable Zero Pressure Logic YES Take a ZeroCFM Reading LOCKED Value OA SensorVoltagezeroCorrect 0 25 V PE_SensorVoltagezeroCortect 0 24 v ActOACEM 0 GFM AGtEXCFM D esu OAU_LAT grogne OAU_EXAT 8 00 f JE CANCEL tt DECR It INCR MUTE FN C12811 Fig 47 Scroll Down to View CFM Readings After completing the ERV test it is important to reset all values to the defaults and to turn off the
74. iew performance leave the Row Count value set to 4 as that is the number of lines on the handheld BACview screen It is recommended that you increase this number as it will make the navigation a bit easier Select the appropriate COM port number from the previous step in the pull down window and click OK From this point on the directions for the Handheld BACview and the Virtual BACview Software are the same Upon initial connection BACview displays the message shown in Fig 36 El Virtual BACview C12800 Fig 36 Waiting for Connection After a few seconds the Stand By screen as seen in Fig 37 appears C12801 Fig 37 BACview Stand By Screen Press any key and you will see the HOME screen as pictured in Fig 38 sl Eile Configure Help a BACview Gatrier Energyx2 ERY IOFLEX 6126 HVAC STATUS 2 HVAC TEST FACTORY ERV TEST SERV CONFIGURATIONS ERV STATUS gt CFM STATION INFO gt ERV CONFIGURATIONS 2DATA CONNECTIONS gt VER SOFTWARE 3ERV RAW IO Olock8Set SHELP Energyx2 ERV IOP ALARM A 000000 6 7 8 9 o ENTER KL e e e 6 e e e e 9 K A K C12802 Fig 38 Home Screen with Main Menu Displayed Using the arrow keys you can navigate up and down this selection list To see the current values of sensor readings and output states of the main RTU select HVAC STATUS To put the RTU into a TEST mode and exercise the outputs select HVAC TEST To p
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77. lternating Ten second recovery period after with Run LED brownout 14 flashes per second 14 flashes per second alternating Brownout with Run LED On On Failure Try the following solutions Turn the I O Flex 6126 off then on Download memory to the I O Flex 6126 Replace the I O Flex 6126 Serial Number If you need the I O Flex 6126 s serial number when troubleshooting the number is on a sticker on the back of the I O Flex controller board a Module Status report modstat from WebCTRL 56 Compliance FCC Compliance This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense p CAUTION EQUIPMENT OPERATION HAZARD Failure to follow this caution can result voiding the user s authority to operate the equipment Changes or modifications not expressly approved by the responsible party for compliance could void the
78. mp down to 0 speed shut off The exhaust fan will run at a speed equal to the required offset CFM Refer to Exhaust Control for details on determining offset CFM ERV DCV Mode General ERV Mode ERV Mode is the basic operating mode of the ERV With no options installed on the ERV this will be the only operating mode besides off and test ERV Mode will be active when the rooftop mode is Heating Cooling Fan Only or Dehumidification and the ERV is occupied DCV ERV Mode will be active when the rooftop mode is Heating Cooling Fan Only or Dehumidification and the ERV is occupied When in DCV ERV mode the wheel will be rotating The outside air fan will run at a speed that produces a CFM equal to the minimum outside air CFM determined by Demand Control Ventilation DCV The exhaust fan will run at a speed equal to the required offset CFM Refer to Exhaust Control for details on determining offset CFM Switch Demand Control Ventilation DCV uses the indoor air quality levels High Low to determine how much outside air is required for ventilation The ERV monitors the IAQ switch reading from the rooftop s installed CO switch The minimum outside air CFM will be equal to one of the following Min DCV outside air CFM setpoint or the minimum outside air CFM setpoint If the CO switch reads low the outside air CFM requirement will be DCV M If the switch reads high the outside air CFM requirement will be OA MN The outside ai
79. nd down and make additional changes to the output states in order to test them 59 EnergyX Esl virtual BACview E File Configure Help BACview T 0 FLEX 6126 7 11 TURN TEST MODE ON FAN 8 8 FAN SPEED POWER EXHAUST coon 1 8 8 Coop 2 s s on off 33 off off off io xj off oft OA DAMPER POS 307 OR JI CANCEL it DECR 1t INCR MUTE FN C12806 Fig 42 Value Changed OA DAMPER POS When you are done testing the outputs change the TURN TEST MODE ON variable to OFF and click ENTER to turn off the test mode and put the RTU in AUTO mode see Fig 43 mixi File Configure Help BACview r o FLEX 6126 7 11 TURN TEST MODE ON Off FAN 8 8 Off 83 Off off off off off OA DAMPER POS 30 gt HOME SSTATUS C12807 Fig 43 HVAC Test Completed To run the ERV Test from the Home screen see Fig 38 select FACTORY ERV TEST and then press ENTER The screen shown in Fig 44 appears To start the test select and change LCD LOCAL FACTORY TEST variable to YES see Fig 45 After this you can change the values for any of the ERV outputs thus controlling the Wheel operation as well as the speed of the OA and EX fans see Fig 46 Eet lose File Configure Help BACview Z77EACTORY TEST LCD LOCAL FACTROY TEST Long OADMPR OFF LED_S_WHEEL u LCD_S_OAFAN a LGD 8 EXFAN LCD 8 OAHEAT a Zero Press Sensor for CFM STATION Enable Zero Pressure Log
80. nd testing the ERV verify that the minimum damper positions are set to 0 and if not change them to 0 OPERATING SEQUENCE General An EnergyX unit is a 48 50HC rooftop unit and energy recovery ventilator ERV It operates the ERV module in an integrated manner with the base rooftop unit The base rooftop unit functions per the base unit sequence of operation The ERV will operate based on communication from the I O Flex 6126 controller The following section discusses the ERV operation in detail In summary the ERV operates to provide pre conditioned outside air for ventilation requirements In general the ERV monitors occupancy and indoor fan state of the base unit to determine when to activate The outside air fan bring in outside air which passes it through the enthalpy wheel and into the rooftop unit The building return air is pulled through the enthalpy wheel by the exhaust fan and released outside During operation the enthalpy wheel is rotating to use the building air to pre condition the outside air IMPORTANT Refer to Appendix D for details on the I O Flex controller for the EnergyX system Communication The ERV relies on communication with I O Flex 6126 to operate The ERV monitors I O Flex 6126 points to determine operation The ERV writes to values in I O Flex 6126 to provide the user with its running status If communication is lost the ERV will shut down and remain in the Off mode until communication is established
81. nergyX unit with a curb adapter the curb adapter must be secured to existing curb and the curb adapter secured to the unit with hold down brackets See the rigging label on the exterior of the base unit and Fig 2 This label is provided for guidance purposes ONLY The unit s actual weight and center of gravity will vary based on the specific combination of factory options included with the unit Use prudent judgment when rigging and lifting the unit to account for weight variances and make adjustments for the actual center of gravity as necessary NOTE Hold down brackets must be affixed to the curb and rooftop unit prior to removing rigging support SCREW LOCATION TYPICAL 8 PLACES RTU HOLD DOWN BRACKET SUPPLY RETURN AIR AIR Tesco HOLD DOWN BRACKETS PROVIDED BY ROOF CURB MANUFACTURER TYPICAL 4 PLACES BRACKET LOCATION ON ROOF CURB INSTALL BRACKETS WITH THE TEK SCREWS INCLUDED BY THE ROOF CURB MANUFACTURER 8 SCREWS PER BRACKET SEE DETAIL BELOW BRACKET INSTALLATION TO BASE RAIL ROOFTOP UNIT NEOPRENE GASKET WOOD NAILER TEK SCREW TYPICAL SUPPLIED BY ROOF CURB MANUFACTURER BRACKET SUPPLIED Em BY ROOF CURB a MANUFACTURER ud u gt b RIGID INSULATION M ROOF CURB I ROOF MEMBRANE VIN ze ROOF DECK DETAIL RTU HOLD DOWN BRACKET INSTALLATION
82. not replaceable and will reset themselves if the condition that caused the fault returns to normal Rx Lights when the controller receives data from the network segment there is a Rx LED for Ports 1 and 2 Tx Lights when the controller transmits data to the network segment there is a Tx LED for Ports 1 and 2 Lights based on the controllers health See table below Lights based on the controllers health See table below The Run and Error LED s indicate controller and network status If Run LED shows And Error LED shows Status is 1 flash per second 1 flash per second alternating The controller files are archiving Archive with the Run LED is complete when Error LED stops flashing 2 flashes per second 2 flashes Five minute auto restart delay after alternating with Run LED system error 2 flashes per second 3 flashes The controller has just been formatted then off 2 flashes per second On Two or more devices on this network have the same MS TP network address 2 flashes per second 1 flash per second The controller is alone on the network 2 flashes per second O Exec halted after frequent system errors due to Controller halted Program memory corrupted Address conflicts duplicate MS TP MAC addresses One or more programs stopped 5 flashes per second O Exec start up aborted Boot is running 5 flashes per second Off Firmware transfer in progress Boot is running 7 flashes per second 7 flashes per second a
83. nstruction and is to be used in conjunction with the base rooftop unit Installation Instructions The EnergyX Energy Recovery system is designed to pre condition the outside air prior to it entering the rooftop unit evaporator using building exhaust air as a heat sink source The EnergyX system provides latent and sensible energy exchange between the outside ventilation air and the building exhaust air This preconditioning of air allows higher operating efficiencies increased comfort control potential downsizing of the base rooftop unit while still meeting the ASHRAE ventilation requirements Operational cost savings are realized by the high efficiency Energy Recovery device meeting the cooling and heating call for a larger portion of the operating cycle than just a normal damper or economizer device This is demonstrated by the EnergyX AHRI Guideline V Combined Efficiency Factor EnergyX HC24 28 units are shipped in the vertical supply and return duct configurations only A field installed horizontal curb adapter kit is available for horizontal return and supply configuration The EnergyX Energy Recovery Wheel is rated in accordance with AHRI 1060 and is UL listed See Table 1 for Physical Data EnergyX Physical Data Table 1 Physical Data uo Immens ENERGY RECOVERY WHEEL super Base BLOWER SIZE 19 68 in 500mm me 2 in Pleated 30 Efficiency 2 20 in x 20 in x 2 in 2 20 in x 20 in x 2 in S
84. nt is needed 1 Loosen diameter seal adjusting screws and back seals away from the wheel surface See Fig 8 Rotation To ALLY X Z 5 Adjusting Screws Feeler Gauge C11469 Fig 8 Diameter Seal Adjustment 19 EnergyX 2 Rotate the wheel clockwise until two opposing spokes are hidden behind the bearing support beam 3 Using a folded piece of paper as a feeder gauge posi tion the paper between the seal and wheel surface 4 Adjust the seal towards wheel surface until a slight friction on the feeder gauge paper is detected while moving the gauge along the length of the spoke 5 Re tighten adjustment screws and re check clearance with the feeder gauge Wheel and Segment Removal Installation The wheel and segments represent a substantial portion of the value of the cassette therefore must be handled with care and never be dropped Use a suitable crate or harness to lift wheel and segments to a roof surface never use the shipping cartons for this purpose Wheel and segments may require slight persuasion during installation and removal but never forced or impacted with a hammer or similar tool The wheel assembly can be removed and installed or the wheel or segments can be removed from the assembly A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage The weight of the wheel assembly must b
85. of the ad dress and set the Ones 1 s switch to the ones digit 1 Turn off the I O Flex 6126 s power to prevent it from EXAMPLE If the controller s address is 25 point powering up before you can verify the correct voltage the arrow on the Tens 10 s switch to 2 and the arrow 2 Remove power from the 24 Vac transformer on the Ones 1 s switch to 5 See the figure below 3 Pull the screw terminal connector from the E controller s power terminals labeled Gnd and 24 Vac 10 s MAN 4 Connect the transformer wires to the screw terminal 9 S A connector E 5 Apply power to the transformer 1 s Oe 6 Measure the voltage at the I O Flex 6126 s power in e put terminals to verify that the voltage is within the operating range of 21 6 26 4 Vac C12790 NOTE The I O Flex 6126 recognizes its address only after power has been cycled gt Insert the screw terminal connector into the I O Flex 6126 s power terminals Turn on the I O Flex 6126 s power Verify that the Power LED is on and the Run LED is blinking o Wiring Inputs and Outputs Input Wiring Specifications 0 5 Vdc 1000 feet 305 meters 26 AWG Shielded 0 20 mA 3000 feet 914 meters 26 AWG Shielded or Unshielded Thermistor 1000 feet 305 meters 22 AWG Shielded Dry Contact Pulse Counter CONAN 100 100 feet 30 meters 30 100 feet 30 meters 22 22ANG Shielded ae Sensor 500 feet 152 meters 19 2M n 4 conduct
86. oltage pressure characteristics of each Table 5 Transducer Voltage vs Pressure Voltage Pressure inWC po SE a EnergyX Control Board LEDs The EnergyX Control Board EXCB has five green LEDs and one red LED The red LED is for power indication and the green LEDs are status indicators see Table 6 for details MAJOR SYSTEM COMPONENTS An EnergyX unit has a factory installed energy recovery ERV device on a 48 50HC rooftop unit The EnergyX energy recovery unit is integrated into the base rooftop unit construction and is factory wired The energy recovery unit contains a control box supply fan exhaust fan and an enthalpy wheel assembly All control operations of the ERV are based on the rooftop units operation through communication with I O Flex 6126 See Fig 5 and 6 for ERV wiring schematic and component arrangement Table 6 EXCB LED Indicators COLOR DESCRIPTION STATUS IF LIGHT IS LIT D9 Rea X 24vAC board power Board has power Run light Flashing ERV is Running 1 Requires installation of optional Wheel Motion sensor 2 Requires installation of optional Frost sensor 3 Requires installation of optional Filter sensor 14 S844c19 JYEULDYOS ZUM AYA Sunepnpo y S 2141
87. or if a BACview is connected to the Rnet EL or Unshielded 22 AWG 4 conductor if only RS room sensors are connected Inputs The I O Flex 6126 has 12 inputs that accept the signal types described below These Support this c signal type Description Thermistor Precon type 2 10 kOhm at 77F Input voltages should be from 0 489 Vdc to 3 825 Vdc for thermistors RTD 0 20 mA The input impedance of the I O Flex 6126 is approximately 1 Mohm 0 10 Vdc All Dry Contact A 5 Vdc wetting voltage detects contact position resulting in a 0 5 mA maximum sense current when the contacts are closed Ul 1 UI 2 Pulse Input Maximum of 10 pulses per second Minimum pulse width required for each pulse ON to OFF time half cycle is 50 msec ON to OFF to ON time full cycle is 100 msec 54 Local Access To Communicate Through the Local Access Port Use a computer and a USB Link Kit to communicate locally with the I O Flex 6126 to download or to troubleshoot Prerequisites A computer with a USB port AUSB Link Kit p CAUTION EQUIPMENT DAMAGE HAZARD Failure to follow this caution may cause equipment damage Failure to maintain polarity while using the USB Link on a computer that is grounded via its AC adapter may damage the USB Link and the I O Flex 6126 controller f wary of the integrity of electrical work and the computer is running on AC power use a USB isolator secured through a third party manufacturer Firs
88. orks SLTA Port2b For LonWorks Option Card Rnet port For connecting to RS sensors and or BACview Supports any of the following e 1 RS Plus RS Pro or RS Pro F e 1 4 RS Standards e 1 4 RS Standards and 1 RS Plus RS Pro or RS Pro F Any of the above combinations plus up to 2 BACview but no more than 6 devices total Local Access port For local communication with a laptop computer running WebCTRL or for communications with a BACview Universal inputs 12 inputs configurable for 0 10 V RTD Therm Dry or 0 20mA Inputs 1 and 2 may bye used for pulse counting Input pulse frequency Maximum of 10 pulses per second Minimum pulse width required for each pulse ON to OFF time half cycle is 50 msec ON to OFF to ON time full cycle is 100 msec Binary outputs 6 binary outputs relay contacts rated at 5A max 9 250 Vac Configured normally open or normally closed Analog outputs 6 analog outputs Inputs 1 and 2 are configurable for 0 10 V or 0 20nA 3 6 are 0 10 V only 1 MB non volatile battery backed RAM 1 MB Flash memory 16 bit memory bus Real time clock Battery backed real time clock keeps track of time in event of power failure Battery 10 year Lithium CR2032 battery provides a minimum of 10 000 hours of data retention during power outages Protection Incoming power and network connections non replaceable internal solid state polyswitches reset themselves when fault clears Power network I O connections
89. r fan will ramp its speed up or down to produce the required CFM Exhaust Control When the Power Exhaust control is set to Offset CFM the ERV exhaust fan operate to offset the outside air being introduced to the building The required exhaust offset CFM is determined based on the exhaust offset setpoint The exhaust offset setpoint can be set as a negative or positive number to accommodate a requirement of positive or negative building pressure A positive setpoint will produce a negative building pressure A negative setpoint will produce a positive building pressure The ERV will determine the required amount of outside air CFM based on setpoints and current mode of operation The commanded exhaust air CFM is then calculated by the sum of the actual outside air CFM and the exhaust air offset setpoint During defrost mode the exhaust will run the same as if the outside air fan were still running TROUBLESHOOTING EnergyX units are a combination of the base rooftop unit and an integrated ERV The ERV requires communication from the rooftop for operation This section covers ERV troubleshooting only For rooftop troubleshooting refer to the base unit s Service manual Complete ERV Stoppage There are several conditions that can cause the ERV to shutdown or appear to be shutdown General power failure Transformer s circuit breaker tripped ERV main power fuses blown Communication failures Active alarm on the base
90. r return air contact your Carrier Sales Engineer for additional guidance prior to specification or ordering 2 50 3 00 External Static Pressure in H20 C12786 Fig 30 20 amp 25 Ton MRT Unit ERV Supply and Exhaust Fan Performance Curves xADJ1ou3 euin SIU 1e AH3 YM peddinbe syun 264e 10 e qelreAe Jou 1eziuouo93 x 6v eDed uo s 8 se qe 104 sejoN pue pueDej eeg ozz 99 02 L 09 ozz 99 02 L 09 892 e9 02 res 892 e9 02 ves HOM o eve e9 02 Ce gre e9 02 Ce Lwa 19 02 999 L 19 02 ECH aan n Sz 09 09 798 Ga 09 09 298 erz gs 09 P erz gs 09 srs ais oe e8 06 zu 196 e8 06 zu ese 18 06 gei ese 18 06 Gei HOM a Ize A4 06 SI Ize A4 06 SI 61 vL 08 Ce 61 vL 08 e 69 GZW if 8Z OH8v eze vL 08 Cen eze vL 08 Cen Ize E 08 Lg E 2 08 Lg ais gt 802 GL ooz 0 891 07 ezi 002 0891 869 vL 002 z e9L 869 vL 002 Ce HOIH S teg 991 002 9951 teg 991 002 9951 619 oi SLL 816i 619 i9 SZL get aan 2 Ww szo avar oozjocz sssuue czo iomzor ooziooz zawiesi czo savar suat vueen czo esum suen rerieen os 8 gr 09 09 Ce gr 09 09 Ce rr gs 09 ses pr gs 09 ses HOM o eiz gs 09 Ces eiz gs 09 Ces Az 98 09 916 Az 9g 09 916 aan f 8 Izz gg 09 els Izz gg 09 els 6iz rS 09 ger 6iz rS 09 ger ais Gee BL 08 SL gee 82 08 814 eee SZ 08 9 69 eee SL 08 969 HOIH oe v 08 L 99 oe v 08 L 99 sez
91. rability 5 Remove the four bolts holding the front fan panel onto the rest of the outside air fan assembly Completely remove this panel from the ERV NOTE Tilt the fan assembly front panel to fit it through the hood opening 6 Pull the outside air fan out through the hood opening See Fig 17 NOTE Tilt the fan assembly to fit its back panel through the opening in the dividing wall 23 EnergyX Outside Air Fan Assembly see Detail A Detail A Outside Air Fan Assembly Remove Fasteners 4 Places Remove Bolts 4 Places C13028 Fig 16 Remove Fasteners from Corners of Outside Air Fan Assembly Fig 17 Outside Air Fan Removal 24 NOTE To meet building codes the exhaust hood sides may be cut out on some 25 ton units C13029 Exhaust Fan Removal 1 Turn off lockout and tag out electrical power to unit 2 Remove the exhaust air hood see procedure on page 23 3 Open the door to the EnergyX unit in order to gain access to the exhaust fan front panel NOTE See instructions for removing the wheel and exhaust filters if more room is needed to access the exhaust fan front panel 4 Remove the fasteners around the perimeter of the exhaust fan that secure the exhaust fan front panel to Detail A Exhaust Fan Assembly secured to Dividing Wall
92. rooftop unit or the ERV preventing operation Review alarms 13 EnergyX Programmed occupancy schedule Rooftop Unoccupied Rooftop indoor fan is off The airflow sensor tubing connected to the incorrect high low sensor ports in the outside air Wheel Status Option NOTE Wheel Status requires installation of the optional wheel motion sensor This alarm will occur when the ERV wheel is turned on and the wheel proxy sensor does not detect wheel motion within the set time It will open its contact which energizes the normally closed rotation monitor relay This alarm will automatically reset when motion is detected Possible causes of this alarm are the wheel belt breaking or slipping wheel motor failure proxy sensor failure or incorrect setting or wiring error On board Pressure Transducers The EXCB uses on board pressure transducers to measure the air pressure of the incoming outside air and the building exhaust air The CFM values are then calculated based on these readings and the fan speed There is a pressure transducer for the outside air and one for the exhaust air These are screwed into the EXCB board to J24 and J25 respectively They have three pins IN GND and OUT The IN pin is 5vdc input power and GND is the common or ground pin The OUT pin will be 0 26 to 4 5vdc based on the pressure reading There are two different transducers used two inch of water column inWC and 5 inWC Table 5 shows the v
93. rr CH 06 c 68 Lv 9 6v 00v98c HOIH 9vc 09 02 919 9vc 09 02 949 trr 99 09 S 6S tr 99 09 S 6S DEC 8 ve 00vs8c 9vc 09 09 ss 9vc 09 09 ess tr 99 09 Ges tr 99 09 S ES CS ANON BLZ 604 OLL 6004 BLZ 604 DEE 6004 zle 204 004 886 zle ZOL 004 886 914 vv 00v28c a BLZ CH 06 0 68 BLZ CH 06 0 68 zle 08 06 8 98 zle 08 06 8 98 Ly 9 6r 00v98c aan L BLZ 9S 09 26S BLZ 9S 09 469 Ze 99 09 VZS YAYA 99 09 FZS DEG 8 ve 00vs8c BLZ 99 09 ees BLZ 99 09 ECG zle 9S 09 OLS zle 99 09 EN m ANON gt Lec 204 004 v 96 Lac 204 004 v 86 BLZ SOL 004 96 BLZ SOL 004 96 914 vol 00v28c Lec 08 06 G 98 LGG 09 06 S 98 BLZ 82 06 evs BLZ 82 06 evs Ly 9 6r 00v98c ais Lec SS 09 29S Le SS 09 L9G BLZ TS 09 9vg BLZ TS 09 EK 6 Ee 8vc 00vs8c Lec SS 09 e LG Lec SS 09 e LG BLZ TS 09 9 6v BLZ TS 09 9 6r ANON Gee BEL OSL Geel see BEL OSL Geel eee DCL OSL 8 ScL eee DCL OSL 8 ScL 706 052 00vv8c Gee POL 001 v 96 see POL 004 786 eee cOl 004 Jop eee ZOL 004 256 F09 0 0S oovese HOIH Gee 82 08 092 See 82 08 092 eee S 08 cel 223 GL 08 ce LO ose oovese see 82 08 8 LL see 82 08 8 LL eee S 08 9 69 eee S 08 9 69 ES ANON G6c cel Sel Viel S6c cel Sel viel 6c DEL Gel DKCH 6c UCL Gel DKCH 706 052 00vv8c 3 G6c 86 001 16 G6c 86 004 ele EDC S6 06 9 88 6c S6 06 9 88 109 005 oovese aan B PZxx S6c LZ 09 999 S6c LZ 09 999 E 69 08 Log 6c 69 08 Log LO ose oovese b 9HOS G6c LZ 09 Log G6c LZ 09 F99 EDC 69 08 6e9 6c 69 08 GO ANON E 466 DEL set KI 46c DEL Sel Z8LL S6c Zeb Gel 6sglL S6c zel Gel
94. t plug the USB isolator into the computer s USB port then connect the USB Link to the isolator If using the USB Link Kit with your computer for the first time install the USB Link Kit s driver before connecting the cable to the computer a Put the USB Link Driver CD or WebCTRL install DVD into the computer b Install the USB Link Driver accepting all of the wizard s default settings 2 Connect the USB Link Kit to the computer and to the I O Flex 6126 controller s Local Access port Connect to Connect to computer s the Local USB port Access port 2 ea Sl TN USB Link Kit C12795 Rnet Wiring Specifications NOTE Use the specified type of wire and cable for maximum signal integrity Description 4 conductor shielded or unshielded CMP plenum rated cable Conductor 22 AWG 7x0096 bare copper if Rnet has only RS sensors 18 AWG 7x0152 bare copper if Rnet has a BACview Maximum length 500 feet 152 meters If shielded Aluminum Mylar shield 100 coverage with TC drain wire Wiring an RS Room Sensor to the I O Flex 6126 The I O Flex 6126 supports up to 5 RS sensors on its BACview RS sensor port RS sensors can be wired to the I O Flex 6126 s Rnet port in any of the following combinations 1 RS Plus RS Prow or RS Pro F 1 4 RS Standards s 1 4 RS Standards and 1 RS Plus RS Pro or RS Pro F The RS Pro is a thermistor based temperature sensor To Wire an RS Room
95. the device manager to make a note of the COM port number the USB adapter got mapped to Fig 34 shows an example of this screen and in this case the COM port is COM 6 P Computer Management sie xl File Action View Help Alm B u Computer Management Loca E E System Tools 8 Y Task Scheduler E EJ Event Viewer fl Shared Folders ilie Local Users and Groups Performance Device Manager JINI Computer cs Disk drives More Actions V Display adapters ed DVD CD ROM drives mi Human Interface Devices gt Keyboards Y D Mice and other pointing devices V Modems IL Monitors E Network adapters Y I Portable Devices EF Ports COM amp LPT T Communications Port COM1 YY Communications Port COM2 ECP Printer Port LPT1 T9 RIM Virtual Serial Port v2 COM4 Y RIM Virtual Serial Port v2 COMS T Silicon Labs CP210x USB to UART Bridge COM6 D Processors X Sound video and game controllers lt Storage controllers E System devices Universal Serial Bus controllers USB Virtualization SP Disk Management Els Services and Applications C12798 Fig 34 COM Port Used Example After you ve made a note of the COM port number launch the Virtual BACview software Fig 35 shows the initial screen xi Row Count 4 Comm Port COM6 m C12799 Fig 35 Virtual BACview Connection Startup Settings If you want to simulate the handheld BACv
96. ts until the water runs clear 7 Allow excess water to drain prior to replacing seg ments in the wheel A small amount of water remain ing in the wheel will be dried out by the airflow Filters Clean or replace at start of each heating and cooling seasons or more often if operating conditions require based on filter manufacture recommendation or filter status alarm indication Refer to Table 1 for type and size of filters Outdoor Air Inlet Screens Clean screens with steam or hot water and a mild detergent at the beginning of each heating and cooling season Do not use throwaway filters in place of screens Lubrication All component bearings are sealed and do not require lubrication Wheel Drive Adjustment The wheel motor and drives do not require adjustment The wheel drive pulley is secured to the drive motor shaft by a set screw The set screw is secured with removable locktite to prevent loosening Annually confirm set screw is secure The wheel drive belt is a urethane stretch belt designed to provide constant tension throughout the life of the belt Inspect the drive belt annually for proper tracking and tension A properly tensioned belt will turn the wheel immediately after power is applied with no visible slippage during start up Wheel Air Seal Adjustment Diameter seals are provided on each wheel cassette to minimize transfer of air between the counter flowing airstreams Follow below instructions if adjustme
97. use explosion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified installer service agency or your distributor or branch for information or assistance The qualified installer or agency must use factory authorized kits or accessories when modifying this product Refer to the individual instructions packaged with the kits or accessories when installing Follow all safety codes Wear safety glasses and work gloves Use quenching cloths for brazing operations and have a fire extinguisher available Read these instructions thoroughly and follow all warnings or cautions attached to the unit Consult local building codes and appropriate national electrical codes in USA ANSI NFPA70 National Electrical Code NEC in Canada CSA C22 1 for special requirements It is important to recognize safety information This is the safety alert symbol AN When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING CAUTION and NOTE These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage NOTE is used to
98. user s authority to operate the equipment CE Compliance A WARNING RADIO INTERFERENCE HAZARD Failure to follow this warning could result in radio interference near by equipment This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures BACnet Compliance BACnet is a registered trademark of ASHRAE ASHRAE does not endorse approve or test products for compliance with ASHRAE standards Compliance of listed products to requirements of ASHRAE Standard 135 is the responsibility of the BACnet manufacturers Association BMA BTL is a registered trademark of the BMA 57 EnergyX APPENDIX E CARRIER BACview VIRTUAL BACview COMMISSIONING This appendix shows screen captures from the Virtual BACview software however the procedure is the same regardless of which method of connection is utilized If you are using the handheld BACview 6 simply plug in the brown R net connector at the end of the cable to the Rnet Local Access port on the I O Flex 6126 The connector is keyed and polarity sensitive It should fit in only one way If you are using the Virtual BACview Software with the USB K connection cable use the 4 pin adapter and not the round barrel connector After you ve installed the software plug the cable into any USB port on your laptop and after the adapter has been detected and installed go to
99. ut the ERV into a TEST mode and exercise the outputs select FACTORY ERV TEST The rest of the options are additional status screens which you may select if interested To view the HVAC Status select HVAC STATUS the screen in Fig 39 appears etui Babe a GER File Configure Help 1 0 FLEX 6126 TARGET I O SUMMARY INPUTS STEST MODE MUTE FN C12803 Fig 39 HVAC Status Screen You can scroll down the list to see all input and output statuses Select HOME to go back to the main menu or TEST MODE to go to HVAC TEST If you pick TEST MODE the screen shown in Fig 40 appears El Virtual BACview File Configure Help I O FLEX 6126 7 11 ON oft otf 33 off oft off Off off OA DAMPER POS D 3HOME 8TATUS ALARM MUTE FN C12804 Fig 40 HVAC Test Initial Screen To start the test place the cursor on the TURN TEST MODE ON and press ENTER The screen shown in Fig 41 appears BER File Configure Help OA DAMPER POS OR 1t CANCEL tt DEGR INCR MUTE FN C12805 Fig 41 HVAC Test Test Mode On The function keys below the screen give you the option to OK the change CANCEL DECREMENT or INCREMENT the value To turn the TEST MODE ON Increment the value by 1 change from OFF to ON and press ENTER The RTU will go into TEST MODE and the outputs of the I O Flex 6126 will reflect the values seen on the screen As Fig 42 shows you can scroll up a
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