50R0649xHEN ERGY RE COVERY SYSTEM

WARNINGImproper installation, adjustment, alteration, serviceor maintenance can cause property damage,personal injury or loss of life. Installation and servicemust be performed by a qualified installer or serviceagency.

IN STALLATION IN STRUCTIONS FOR EN ERGY RE COVERY SYS TEMS (ERS)USED WITH 036-060 LC/LG SE RIES UNITS

ETL Certified per UL 1995and CSA 22.2

KITS AND ACCESSORIESR06A-49LDW

July 12, 2010Supersedes 02-15-10

SHIP PING AND PACK ING LIST

Package 1 of 1 contains: See Illustration 1 and 2.1 - Energy Recovery System Assembly 1 - Outdoor Fresh Air Hood with Filter 1 - Outdoor Exhaust Air Hood with Barometric

Damper 1 - ERS Support Rail1 - Adaptor Panel1 - Balancing Damper Assembly 1 - Door Panel1 - Hardware Bag:

14' - Gasket ¾" x 1 ¼" 7' - Gasket 1

8" x ½" 1 - Field Harness 4 - Wire Ties

12 - Self-Tapping Screws 10-16 x ½" 6 - Mounting Screws 14-16 x ¾"8 - Gold Screws 10-16 x ½" 1 - Installation Instruction

The ERS enthalpy wheel contains parallel layers of apolymeric material that are impregnated with silica gel(desiccant). The wheel is located in the entering (intake)air and exhaust air streams of the ventilation equipment.As the wheel rotates through each air stream, the wheelsurface adsorbs sensible and latent energy. In the heatingmode, the wheel rotates to provide a constant transfer ofheat from the exhaust air stream to the colder intake airstream. During the cooling season, the process isreversed.

PRIN CI PLE OF OPERATION

Patent# 5,548,970

8

34 916

24 58

Illustration 1

24 ¾

ADAPTOR PANEL

PLATFORM SUPPORT RAIL

DOOR PANEL

TELE SCOP ING LEG

Illustration 2

FRESH AIR BLOWER

EX HAUST FAN

WIR INGMAKEUP

BOX

MIXED AIR

RETURN AIR

8 34 916

24 58

24 ¾

OUT DOOR AIR DAMPERS

FRESHAIR

EXHAUST AIR

MIXED AIR OUTDOOR AIR

FIL TER ACCESS

EN ERGYRE COV ERY

WHEEL

RETURN/EXHAUST AIR

CON TROL BOARD

POWER EN TRY

PAGE 1

PAGE 2

Figure 1

ROOF TOP UNIT PREPARATION

1. Maximum weight of unit is — 190 Lbs (crated).

2. Remove crating and retrieve hardware bag that isinside of ERS.

3. All ERS door panels must be in place for rigging.

4. Use straps to lift unit.

1. Disconnect all power to rooftop unit.

2. Open filter access door.

3. Remove the rooftop unit horizontal return air accesspanels. Also remove any hoods and/or power exhaustequipment. If economizer is installed it MUST BEremoved. Discard hoods, power exhaust equipment,and horizontal return air panels. See Figure 1.

REMOVE PANEL

CAUTION

GENERAL

REQUIREMENTS

SHIP PING DAMAGE

RIG GING UNIT FOR LIFTING

These instructions are intended as a general guide and donot supersede local codes in any way. Authorities havingjurisdiction should be consulted before installation.

When installed, the unit must be electrically wired andgrounded in accordance with local codes or, in theabsence of local codes, with the current National ElectricCode, ANSI/NFPA No. 70.

Check unit for shipping damage. Receiving party shouldcontact last carrier immediately if shipping damage isfound.

Electric shock hazard. Can cause injury or death. Before attempting to performany service or mai ntenance, turn theelectrical power to unit OFF atdisconnect switch(es). Unit may havemultiple power supplies.

Figure 2

Figure 3

Figure 4

4. If a factory install ERS Harness (J298/P153) isinstalled go to Step 5, otherwise use the providedharness from the hardware bag within the ERS andcomplete the following steps.

A. Locate the field harness from the hardware bagshipped inside the ERS.

B. With door panels open on the control side of RTU,route the wire harness bare ends (3 wires Green,Pink and Black) from return section along the RTUwire at the top of unit and through panel above thefilter rack. See Figure 2.

C. Follow wires all the way through blower section.See Figure 3.

D. Continue to follow wires along the top and throughdivider panel into the control center. See Figure 4.

Figure 6

5. Slide in balancing damper over return duct opening.Put balancing damper in place with the damper bladeat the bottom. See Figure 6 . Loosen wing nut onadjustable quadrant, rotate arm to set blades to 50%open and retighten wing nut. See Figure 7.

Figure 7

WING NUT

6. Using wire ties neatly route the wires to clear anymoving parts.

7. Route the 3-pin connector P153 and wiring harnessunder the balancing damper and out the return air. Coil excess wire and route into return air of the rooftop unit.See Figure 8.

8. Verify the provided adaptor panel is secured to thenew door panel. Also verify the platform support rail issecured to the adaptor panel. See Figure 9.

Figure 5

8 9 10 J298

E. Route wire through the control section down to theM2 Control board. Strip the wire ends 3/8" if theyhave not been pre-done. Place the Green wireunder screw terminal at J298-8 (Purpleconnector). Do the same routine for Pink atJ298-10 and Black to J298-9. See Figure 5.

PAGE 3

Figure 8

WIR ING HAR NESS (P153)

Figure 9

DOOR PANEL

ADAP TOR PANEL

PLAT FORM SUP PORT RAIL

9. Install new door panel over balancing damper andsecure.

Figure 10

Figure 11

PLAT FORM SUP PORT RAIL

ADAP TOR PANEL

Figure 12

TELE SCOP ING LEG

7. Check and seal, if necessary, along the edges wherethe ERS meets the rooftop unit to ensure there is no airleakage. Final assembly should resemble Figure 13.

PAGE 4

Figure 13

8. Remove the right front (rooftop unit side) access paneland locate the field wiring harness that was previouslyrouted into the return air of the rooftop unit. Plug thefield wiring harness into the connector located at thebottom of the access door inside the ERS. See Figure14 and Figure 15.

Figure 14

FIELD HARNESSCONNECTION TO ERS

EQUIPMENT SUPPORT

IN STALL EN ERGY RE COV ERY SYSTEM1. Lift ERS at least three feet (3'). Remove four screws

holding telescoping leg to guide and pull out leg.Reinsert the leg from the bottom with the flat foot under the unit and reinsert one of the screws to hold leg intoplace. The leg will need to be adjusted later when unitis in position.

2. Apply ¾" x 1 ¼" gasket to top and bottom decks of ERS as shown in the figure. See Figure 10.

3. Position ERS in front of new door panel installed inStep 10. Line up the ERS to the rooftop unit. Ensurethat there are not any screws on the rooftop unit thatwill interfere with the mounting flanges of the ERS andif so remove them. See Figure 11.

Note: Equipment support kit or equivalent should beused under feet of standoff legs to prevent roofpenetration. See Figure 12.

4. Set ERS on platform support rail slide ERS up againstadaptor panel. The side flanges of adaptor panelshould fit inside the posts of ERS. Secure ERS toadaptor panel using the provided 10-16 x ½" screws.See Figure 11.

5. Tuck the top flange of the ERS under the rooftop unittop panel and secure with the existing rooftop unitscrews. See Figure 11.

Figure 16

POWER INLET

KNOCKOUT

9. All electrical connections must conform to any localcodes and the current National Electric Codes (NEC)and Canadian Electric Code (CEC). Refer closely towiring diagram in unit and/or in these instructions forproper connections. Refer to the unit nameplate for the minimum circuit ampacity and maximum over currentprotection size. Electrical data is listed on unit ratingplate and motor nameplates.

10. Connect line voltage power to ERS unit from ERS fieldprovided or rooftop unit disconnect switch (disconnectmust be properly sized). Then connect line voltagefrom disconnect switch through ERS knockout onback panel to control box per the wiring diagram. SeeFigure 16.

11. Ground unit with a suitable ground connection eitherthrough unit supply wiring or earth ground.

Note: Unit voltage entries must be sealed weathertight after wiring is complete.

12. Replace access panels onto the ERS unit and secure.

PAGE 5

ROOF TOP UNIT WIR ING(See Field Wir ing Dia gram)

1. Open access panel to rooftop unit controls.

2. The minimum damper blade position must be adjusted on the IMC2 control board to the correct amount ofoutside air specified by the customer. Refer to Lennoxrooftop unit manual for setting.

Wheel AdjustmentThe Electronic Configuration To Order (ECTO)parameter must be set at ECTO 7.22 = 10 to indicateERS is installed.

Smoke Mode Op er a tion

Smoke Mode Set ting(ECTO 5.01) Blower D02 Damper D01

0, unit off (de fault) OFF OFF Closed OFF

1, pos. pressure ON OFF 100% Open ON

3. Close access panels on the rooftop unit and secure.

4. Restore power to unit.

5. Once ERS is working properly, caulk any open joints,holes, or seams to make the units completely air andwater tight.

6. Leave this instruction manual with owner or in anenvelope to be kept near unit.

During default operation the ERS will start when theRTU unit blower is on.

The A55 (IMC2) uses the following parameters tocontrol ERS. See Figure 17.

For Smoke Mode reference the Sm oke ModeOperation table. Only positve pressure option isavailable.

Notes:1. D01( turns on B28, B26, B27 thru ERS controller) and

D02 are relay outputs from Lennox IMC2 control board.

2. B28 - ERS Wheel Motor, B26 - ERS Exhaust Air Blower, B27 - ERS Fresh Air Blower

At startup, IfECTO 7.22 = 10(ERS Installed)

Blower on &Lennox

economizer >=min. position

ERS onD01 = 1D02 = 0

Power Exhaust onOR

Free-Cooling

ERS onD01 = 1D02 = 1

ERS onD01 = 0D02 = 0

Yes

Yes

Yes

No

No

Nor mal Op er a tion

Figure 17

Figure 15

MAINTENANCE

Motor MaintenanceAll motors use prelubricated sealed bearings; no furtherlubrication is necessary.

Mechanical InspectionMake visual inspection of dampers, linkage assembliesand ERS rotating bearings during routine maintenance.Filters should be checked periodically and cleaned whennecessary. Filter is located in fresh air hoods. DO NOTreplace permanent filters with throwaway type filters.

Energy Wheel MaintenanceAnnual inspection of the self cleaning wheel isrecommended. With power disconnected, remove ERS access panels (rear) and unplug [J150 and P150] (Referto wiring diagrams in this instruction manual). Remove media and wash with water and/or mild detergent. Replace media by reversing the above procedure.

PAGE 6

OPERATION

Re cov ery Wheel ModeOn a thermostat call for blower operation in heating,cooling or continuous blower, the ERS media will rotatebetween fresh air and exhaust air streams. Both the freshair blower and exhaust air blower will be operating.

1. Disconnect ERS main power.

Note: If Low ambient kit S26 is used the jumperbetween TB37-5 & TB37-6 should be removed.Also if system check out is being conducted at lowambient temperatures, jumper low ambientswitch.

2. Open rooftop unit blower access panel and locateTB1. Jumper between "R" (24v) and "G" to energizerooftop unit blower. Refer to manufacturersinstructions when an electronic thermostat or otherenergy management system is used.

3. Restore power to ERS unit. The recovery wheel willrotate in the air stream, fresh air dampers will open,and the blowers will operate.

4. Disconnect main power to unit before makingadjustment to balancing damper and/or ERS unit.

5. Remove all jumpers and replace ERS control accesscover.

6. Set thermostat to normal operating position.

7. Restore power to unit.

SYSTEM CHECK

Figure 18

DELTA PRES SURE EX HAUST AIR

DELTA PRES SURE FRESH AIR

BLOWER SPEED AD JUST MENT

Blower speed selection is accomplished by changing thespeed tap wire (refer to wiring diagram) on both fresh airand exhaust air blowers. All blowers are factory set at"high" for maximum airflow. To determine air flow setting,external static pressure readings will need to be readacross the ERS. Reference Table 1 on page 7. Forlocation to take pressure readings. See Figure 18.

OP TIONAL KITS (Fac tory In stalled)

Motorized Intake Air DamperDamper mounts behind the outdoor air intake hood. Itopens when the ERS is energized and closes whende-energized. Powered by B30 damper motor.

Pressure SensorMeasurement device on the ERS to determine airflowacross the Enthalpy Wheel.

Low Ambient Control Kit (S26)Prevents frost formation on energy wheel heat transfersurfaces by terminating the intake blower operation whendischarge air temperature falls below a field selectabletemperature setting. Intake blower operation resumesoperation after temperature rises above the adjustabletemperature differential.

The frost threshold is the outdoor temperature at whichfrost will begin to form on the ERS wheel. For energyrecovery systems, the frost threshold is typically below10oF. Frost threshold is dependent on indoor temperatureand humidity. The table shows how the frost thresholdtemperatures vary depending on indoor conditions.

FROST THRESH OLD TEM PERA TURE

IN DOOR RH AT 70oFFROST THRESH OLD

TEM PERA TURE

20% 0oF

30% 5oF

40% 10oF

Because Energy Recovery Systems have a low frostthreshold, frost control options are not necessary in manyclimates. Where outdoor temperatures may drop belowthe frost threshold during the ERS operational hours,exhaust only frost control option is available.

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PAGE 7

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Len nox Model No. Req’d Curb Height CFM Range Volt age Phase50R0649xH21 14" 300-550 208- 230 1

50R0649xH23 14" 300-550 208- 230 3

50R0649xH33 14" 300-550 460 3

50R0649xH43 14" 300-550 575 3

PAGE 10

ERS Lay out

Clear ance 24"

Clear ance 18"

"61 ecn araelC

48.000502014414 Roof Curb

012104808Equipment Support

50R0649xH

39.3882.093

Lennox Unit Outline

PAGE 11

NOTES

START UP INFORMATION SHEET VOLTAGE - ERS UNIT

In com ing Volt age L1-L2 L1-L3 L2-L3

Run ning Volt age L1-L2 L 1-L3 L2-L3

Sec ond ary Volt age C (black) to G (green) Volts*

C (black) to W (white) Volts*

* With ther mo stat call ing.

AM PER AGE - ERS MO TORS

In take Mo tor: Nom i nal HP Rated Amps Run ning Amps

Ex haust Mo tor: Nom i nal HP Rated Amps Run ning Amps

Wheel Mo tor: Nom i nal HP Rated Amps Run ning Amps

AIR FLOW

In take De sign CFM Pres sure Drop Cal cu lated CFM

Ex haust De sign CFM Pres sure Drop Cal cu lated CFM

Amb. db Temp Re turn Air db Temp* Tem pered Air db Temp*

Amb. wb Temp Re turn Air wb Temp* Tem pered Air wbTemp*

* Mea sure af ter 15 min utes of run time

IN STAL LA TION CHECK LISTModel # Se rial #

Owner Owner Phone #

Owner Ad dress

In stall ing Con trac tor Start Up Me chanic

q Inspect the unit for transit damage and report any damage on the carrier’s freight bill.

q Check model number to insure it matches the job requirements.

q Install field accessories and unit adapter panels as required. Follow accessory and unit installation manuals.

q Verify field wiring, including the wiring to any accessories.

q Check all multi-tap transformers, to insure they are set to the proper incoming voltage.

q Verify correct belt tension, as well as the belt/pulley alignment. Tighten if needed.

q Prior to energizing the unit, inspect all the electrical connections.

q Power the unit. Bump the motor contactor to check rotation. Three phase motors are synchronized at thefactory. If blower motor fans are running backwards, de-energize power to the unit, then swap two of the threeincoming electrical lines to obtain proper phasing. Re-check.

q Perform all start up procedures outlined in the installation manual shipped with the unit.

q Fill in the Start Up Information as outlined on the opposite side of this sheet.

q Provide owner with information packet. Explain the thermostat and unit operation.

PAGE 12