Greenheck ECV Maintenance Manual

Document 480955

Model ECV

®

Energy Core Ventilator

Installation, Operation and Maintenance Manual

Please read and save these instructions for future reference. Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself and others by observing all safety information. Failure
to comply with these instructions will result in voiding of the product warranty and may result in personal injury
and/or property damage.

Energy Recovery Technical Support

Call 1-800-240-0870

General Safety Information

Only qualified personnel should install this system.
Personnel should have a clear understanding of these
instructions and should be aware of general safety
precautions. Improper installation can result in electric
shock, possible injury due to coming in contact with
moving parts, as well as other potential hazards.
Other considerations may be required if high winds
or seismic activity are present. If more information is
needed, contact a licensed professional engineer before
movingforward.

DANGER

Always disconnect power before working on or near
this equipment. Lock and tag the disconnect switch or
breaker to prevent accidental power up.

CAUTION

When servicing the unit, the internal components may
be hot enough to cause pain or injury. Allow time for
cooling before servicing.

CAUTION

Precaution should be taken in explosive atmospheres.

1. Follow all local electrical and safety codes, as well as
the National Electrical Code (NEC), the National Fire
Protection Agency (NFPA), where applicable. Follow
the Canadian Electrical Code (CEC) in Canada.

2. All moving parts must be free to rotate without
striking or rubbing any stationary objects.

3. Unit must be securely and adequately grounded.

4. Do not spin fan wheel faster than maximum
cataloged fan RPM. Adjustments to fan speed
significantly effects motor load. If the fan RPM is
changed, the motor current should be checked
to make sure it is not exceeding the motor
nameplateamps.

5. Do not allow the power cable to kink or come in
contact with oil, grease, hot surfaces or chemicals.
Replace cord immediately if damaged.

6. Verify that the power source is compatible with
theequipment.

7. Never open access doors to the unit while it
isrunning.

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Table of Contents

Unit Overview

Unit Overview . . . . . . . . . . . . . . . . . . . . . 2

Receiving, Handling and Storage . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . 4

Electrical Information. . . . . . . . . . . . . . . . . . 9

Optional Component Overview . . . . . . . . . . . .12

Start-Up . . . . . . . . . . . . . . . . . . . . . . . .13

Start-Up Components . . . . . . . . . . . . . . . . .15

Optional Start-Up Components . . . . . . . . . . . .16

Routine Maintenance . . . . . . . . . . . . . . . . .20

Troubleshooting . . . . . . . . . . . . . . . . . . . .21

Our Commitment. . . . . . . . . . . . . . . Backcover

Basic Unit

The unit is prewired such that when a call for outside air
is made (via field-supplied 24 VAC control signal wired
to unit control center), the supply and exhaust fans are
energized and optional motorized dampers open. The
unit is normally interlocked (24 volt) to the rooftop air
handler. When the rooftop air handler starts, the auxiliary
contactor in the air handler closes to start the unit.

Summer Operation

Outdoor air is preconditioned (temperature and moisture
levels are decreased) by the transfer of energy from the
cooler, drier return air through the energy recovery core.
The preconditioned air is typically mixed with return air
going back to the air handler for final conditioning.

Outdoor Air

95°F

Exhaust Air

125 grains/lb.

Return Air

75°F

50% RH

Supply Air

82°F

99 grains/lb.

Summer Operation

Winter Operation

Outdoor air is preconditioned (temperature and moisture
levels are increased) by the transfer of energy from
the warmer, more humid return air through the energy
recovery core. The preconditioned air is typically mixed
with return air going back to the air handler for final
conditioning.

Outdoor Air

-13°F

Exhaust Air

1 grains/lb.

Return Air

72 °F

Supply Air

40°F

20 grains/lb.

Winter Operation

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50% RH

Receiving

This product may have been subject to road salt
during transit. If so, immediately wash off all visible
white reside from all exterior surfaces. Upon receiving
the product, check to ensure all items are accounted
for by referencing the delivery receipt or packing list.
Inspect each crate or carton for shipping damage before
accepting delivery. Alert the carrier if any damage is
detected, do not refuse shipment. The customer shall
make notation of damage (or shortage of items) on the
delivery receipt and all copies of the bill of lading should
be countersigned by the delivering carrier. If damaged,
immediately contact your manufacturer’s representative.
Any physical damage to the unit after acceptance is not
the responsibility of the manufacturer.

Handling

Units are to be rigged and moved by the lifting brackets
provided or by the skid when a forklift is used. Location
of brackets varies by model and size. Handle in such
a manner as to keep from scratching or chipping the
coating. Damaged finish may reduce ability of unit to
resist corrosion.

Unpacking

Verify that all required parts and the correct quantity of
each item have been received. Inspect interior of unit
cabinet for any shipped loose items. If any items are
missing, report shortages to your local representative to
arrange for obtaining missing parts. Sometimes it is not
possible that all items for the unit be shipped together
due to availability of transportation and truck space.
Confirmation of shipment(s) must be limited to only
items on the bill of lading.

Storage

Units are protected against damage during shipment. If
the unit cannot be installed and operated immediately,
precautions need to be taken to prevent deterioration of
the unit during storage. The user assumes responsibility
of the unit and accessories while in storage. The
manufacturer will not be responsible for damage during
storage. These suggestions are provided solely as a
convenience to the user.

The ideal environment for the storage of units and
accessories is indoors, above grade, in a low humidity
atmosphere which is sealed to prevent the entry of
blowing dust, rain, or snow. Units designed for outdoor
applications may be stored outdoors. All accessories
must be stored indoors in a clean, dry atmosphere.

Indoor

Maintain temperatures evenly to prevent condensation.
Remove any accumulations of dirt, water, ice, or snow
and wipe dry before moving to indoor storage. To
avoid condensation, allow cold parts to reach room
temperature. Leave coverings loose to permit air
circulation and to allow for periodic inspection.

The unit should be stored at least 3½ in. (89 mm) off
the floor. Clearance should be provided to permit air
circulation and space for inspection.

Outdoor

The unit should be placed on a level surface to prevent
water from leaking into the unit. The unit should be
elevated so that it is above water and snow levels.
Ensure sufficient support to prevent unit from settling
into soft ground. Locate parts far enough apart to
permit air circulation, sunlight, and space for periodic
inspection. To minimize water accumulation, place all
unit parts on blocking supports so that rain water will
run off.

Do not cover parts with plastic film or tarps as these
cause condensation of moisture from the air passing
through heating and cooling cycles.

Inspection and Maintenance

While in storage, inspect units once per month. Keep a
record of inspection and maintenance performed.

If moisture or dirt accumulations are found on parts,
the source should be located and eliminated. At each
inspection, rotate the fan wheel by hand ten to fifteen
revolutions to distribute lubricant on motor. If paint
deterioration begins, consideration should be given to
touch-up or repainting. Units with special coatings may
require special techniques for touch-up or repair.

Machined parts coated with rust preventive should be
restored to good condition promptly if signs of rust
occur. Immediately remove the original rust preventive
coating with petroleum solvent and clean with lint-free
cloths. Polish any remaining rust from surface with
crocus cloth or fine emery paper and oil. Do not destroy
the continuity of the surfaces. Wipe thoroughly clean
with Tectyl® 506 (Ashland Inc.) or the equivalent. For
hard to reach internal surfaces or for occasional use,
consider using Tectyl® 511M Rust Preventive, WD-40®
or the equivalent.

Removing from Storage

As units are removed from storage to be installed
in their final location, they should be protected and
maintained in a similar fashion until the equipment goes
into operation.

Prior to installing the unit and system components,
inspect the unit assembly to make sure it is in working
order.

1. Check all fasteners, set screws on the fan, wheel,
bearings, drive, motor base, and accessories for
tightness.

2. Rotate the fan wheel(s) by hand and assure no parts
are rubbing.

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Installation

RETURN AIR INTAKE

AIR INTAKE

RETURN AIR INTAKE

Outdoor Mounting Options

EXHAUST AIR
DISCHARGE

SUPPLY AIR
DISCHARGE

F

(NON ELECTRICAL SIDE)

A

Outdoor Air Discharge Bottom

Indoor Mounting Options

EXHAUST AIR
DISCHARGE

E

E

SUPPLY AIR
DISCHARGE

(NON ELECTRICAL SIDE)

A

EXHAUST AIR
DISCHARGE

C

SUPPLY AIR
DISCHARGE

G

B

RETURN AIR INTAKE

OUTDOOR

E

(NON ELECTRICAL SIDE)

A

C

G

B

OUTDOOR
AIR INTAKE

RETURN AIR INTAKE

Outdoor Air Discharge End

EXHAUST AIR
DISCHARGE

D

D

B

OUTDOOR AIR INLET

C

RETURN AIR INLET

SUPPLY AIR
DISCHARGE

E

F

(NON ELECTRICAL SIDE)

A

G

OUTDOOR AIR INTAKE

D

C

B

Top and Bottom ConnectionsTop and End Connections

EXHAUST AIR
DISCHARGE

SUPPLY AIR
DISCHARGE

E

E

(NON ELECTRICAL SIDE)

A

D

D

B

OUTDOOR AIR INTAKE

C

Intake and Discharge Options

Bottom Top Side End

OA Intake X X

SA Discharge X X

RA Intake X X

EA Discharge X X

End Connections

Dimensional Data and Weights

Unit
Size

ECV-10 54.8 28.9 43.9 18.4 x 15.9 13.6 x 13.6 8.5 x 11.6 10.3 x 15.2 485

ECV-20 60 43.8 44.9 30.5 x 16 24.5 x 16 23.4 x 14 28 x 13.5 813

ECV-30 60 61.3 44.9 50 x 16 44 x 16 38.1 x 14.5 47.5 x 13.5 1075

ECV-40 60 81 44.9 69.3 x 16 52 x 16 52 x 14.5 66.7 x 13.5 1279

All dimensions are in inches. *Weight assumes outdoor unit with filters, weatherhoods, outdoor air intake damper, controls
and internal double-wall sheet metal.

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Exterior Dimensions Unit Connection Dimensions

A B C D E F G

Approx. Weight*

(lbs.)

Installation

Service Clearances

The ECV unit requires minimum clearances to perform routine maintenance, such as filter replacement and energy
core inspection. Blower and motor assemblies, energy recovery core and filter sections are always provided with a
service door or panel for proper component access. Clearances for component removal may be greater than the

service clearances, refer to drawing below for these dimensions.

NON ELECTRICAL SIDE

BLOWER
CABINET

CORE(S)

Electrical Side Non-Electrical Side Intake End Discharge End

Unit Size

Recommended Minimum Recommended Minimum

ECV-10
ECV-20
ECV-30

36 26 36

ECV-40

All dimensions are in inches.

INTAKE

END

BYPASS DAMPER

(OPTIONAL)

CONTROL

PANEL

ELECTRICAL SIDE

ECV Service Clearance Requirements

Weatherhood

Yes

No Access

Required

33

DISCHARGE

END

Weatherhood NoWeatherhood

Yes

No Access

Required

24

Weatherhood

No

No Access

Required

Electrical Side Non-Electrical Side Intake End Discharge End

Unit Size

Recommended Minimum Recommended Minimum

ECV-10

ECV-20

ECV-30

30

ECV-40

All dimensions are in inches.

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20

20

(25 with

bypass

damper)

ECV Service Clearance Requirements

Weatherhood

30

No Access

Required

Yes

33

Weatherhood NoWeatherhood

Yes

No Access

Required

24

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Weatherhood

No

No Access

Required

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2

1

Installation

Access Panel Locations

The ECV is provided with access panels on both sides of the unit. The non electrical side can be placed against
a wall. Clearance to the electrical side is essential to provide access to the control center and component
maintenance.

1 Control Center

Core, filters, inlet

2

dampers, bypass
dampers, blowers

3 Blowers

1

2

Electrical Side Non Electrical Side

Handling

While this unit was constructed with quality and
dependability in mind, damage still may occur during
handling of the unit for installation.

The system design and installation should follow
accepted industry practice, such as described in the
ASHRAE Handbook. Adequate space should be left
around the unit for filter replacement and maintenance.
Sufficient space should be provided on the side of the
unit for routine service and component removal should
that become necessary.

Lifting

WARNING

All factory provided lifting lugs must be used when
lifting the unit. Failure to comply with this safety
precaution could result in property damage, serious
injury or death.

1. Before lifting, be sure that all shipping material has
been removed from unit.

2. To assist in determining rigging requirements,
weights are shown under the Dimensional Data
and Weights section.

3. Unit must be lifted by all lifting lugs provided on
base structure.

4. Rigger to use suitable mating hardware to attach to
unit lifting lugs.

5. Spreader bar(s) must span the unit to prevent
damage to the cabinet by the lift cables.

6. Always test-lift the unit to check for proper balance
and rigging before hoisting to desired location.

2

3

7. Never lift units by weatherhoods.

8. Never lift units in windy conditions.

9. Preparation of curb and roof openings should be
completed prior to lifting unit to the roof.

10. Check to be sure that gasketing (supplied by
others) has been applied to the curb prior to lifting
the unit and setting on curb.

11. Do not use fork lifts for handling unit.

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Installation

Roof Curb Mounting

Rooftop units require curbs to be mounted first. The
duct connections must be located so they will be clear
of structural members of the building.

1. Factory Supplied Roof Curbs: Roof curbs are
Model GKD. The GKD ships in a knockdown kit
(includes duct adapter) and requires field assembly
(by others). Assembly instructions are included.

2. Install Curb: Locate curb over roof opening and
fasten in place. (Refer to Recommended Roof
Openings). Check that the diagonal dimensions
are within ±1/8 inch of each other and adjust as
necessary. For proper unit operation, it is important
that the installation be level. Shim as required to
level.

3. Install Ductwork: Installation of all ducts should
be done in accordance with SMACNA and AMCA
guidelines. Duct adapter provided to support ducts
prior to setting the unit.

4. Set the Unit: Lift unit to a point directly above the
curb and duct openings. Guide unit while lowering
to align with duct openings. Roof curbs fit inside
the unit base. Make sure the unit is properly seated
on the curb and is level.

5. Fasten the Unit: Fasten the unit to the curb/
equipment support(s) using appropriate methods.
The installer is responsible for determining
appropriate support and fastening methods to
ensure compliance with all applicable codes.

Curb Outside Dimensions and Weights

D

C

A

B

Unit
Size

ECV-10 52.3 26.4 16.5 x 11.5 8.5 x 11.6 60

ECV-20 55.8 39.8 28 x 13.5 25.2 x 15.6 79

ECV-30 55.8 57.7 47.5 x 13.5 42.7 x 15.6 95

ECV-40 55.8 76.8 66.7 x 13.5 54 x 15.6 110

All dimensions are in inches. Weight is for 14-inch high
model GKD curbs.

A B C D

Curb

Weight

(lbs.)

Side of Unit

A

B

C

D

E

Roof Curb

Curb Cap Details for Factory-Supplied Roof Curbs

Unit Size A B C D E

ECV-10 1.9 5.3 4.3 0.8 0.4

ECV-20 1.9 6.8 5.8 1.6 0.4

ECV-30 1.9 6.8 5.8 1.6 0.4

ECV-40 1.9 6.8 5.8 1.6 0.4

All dimensions are in inches.

Base

1-inch Insulation

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Installation

Ductwork Connections

Examples of poor and good fan-to-duct connections
are shown. Airflow out of the fan should
be directed straight or curve the same
direction as the fan
wheel rotates. Poor duct
installation will result in
low airflow and other
system effects.

n

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Recommended Discharge Duct Size and Length

Unit

Size

ECV-10 14 x 14 4

ECV-20 24.5 x 16 6

ECV-30 44 x 16 6

ECV-40 52 x 16 6

• Recommended duct sizes are based on velocities across the cfm
range of each model at approximately 800 feet per minute (FPM)
at minimum airflow and up to 1600 fpm at maximum airflow.
Recommended duct sizes are only intended to be a guide and
may not satisfy the requirements of the project. Refer to plans for
appropriate job specific duct size and/or velocity limitations.

• Straight duct lengths were calculated based on 100% effective
duct length requirements as prescribed in AMCA Publication 201.
Calculated values have been rounded up to nearest foot.

Length of Straight Duct

GOOD

Duct Size

(in.)

Straight Duct

Length

(ft.)

Rail Mounting / Layout

• Rails designed to handle the weight of the unit
should be positioned as shown on the diagram
(rails by others).

• Make sure that rail positioning does not interfere
with the supply air discharge opening or the
exhaust air intake opening on the unit. Avoid area
dimensioned “B” below.

• Rails should extend beyond the unit a minimum of
12 inches on each side.

A

B

Unit Size A B

ECV-10 4.2 11.5

ECV-20 3.1 18.5

ECV-30 3.1 18.5

ECV-40 3.1 18.5

All dimensions are in inches.

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